Fabricating techniques for surgical stapler anvils

ABSTRACT

Methods of manufacturing an anvil for a surgical stapler. In various arrangements, the methods include forming an anvil body by rolling, extruding, metal injection molding or electrochemical machining. Preliminary staple-forming pocket configurations are formed in the anvil body by machining or during the metal injection molding or electro-chemical machining processes. The staple-forming pockets are provided with a final configuration using another manufacturing step such as coining or forging.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of a powered surgical stapling system;

FIG. 2 is a perspective view of an interchangeable surgical shaftassembly of the powered surgical stapling system of FIG. 1;

FIG. 3 is an exploded assembly view of portions of a handle assembly ofthe powered surgical stapling system of FIG. 1;

FIG. 4 is an exploded assembly view of the interchangeable surgicalshaft assembly of FIG. 2;

FIG. 5 is another partial exploded assembly view of a portion of theinterchangeable surgical shaft assembly of FIG. 4;

FIG. 6 is another partial perspective view of an end effector portion ofthe interchangeable surgical shaft assembly of FIG. 2 with jaws thereofin an open position;

FIG. 7 is another perspective view of a portion of the end effector andinterchangeable shaft assembly of FIG. 6;

FIG. 8 is a perspective view of a distal closure member embodiment;

FIG. 9 is an end view of the distal closure member embodiment of FIG. 8;

FIG. 10 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 7, with an anvil and aclosure member thereof in a fully open position;

FIG. 11 is a cross-sectional view of the end effector and closure memberof FIG. 10, taken along line 11-11 in FIG. 10;

FIG. 12 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 11, with the anvil andclosure member in a closed position;

FIG. 13 is a cross-sectional view of the anvil and closure member ofFIG. 12, taken along line 13-13 in FIG. 12;

FIG. 14 is a side elevational view of the end effector and portion ofthe interchangeable surgical tool assembly of FIG. 13, with the anviland closure member thereof in an “over-closed” position;

FIG. 15 is a cross-sectional view of the end effector and closure memberof FIG. 14 taken along line 15-15 of FIG. 14;

FIG. 16 is a perspective view of a portion of another end effector andinterchangeable surgical shaft assembly, with an anvil thereof in anopen position;

FIG. 17 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 16, with the anvil and aclosure member thereof in a fully open position;

FIG. 18 is a cross-sectional view of the end effector and closure memberof FIG. 17, taken along line 18-18 in FIG. 17;

FIG. 19 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 17, with the anvil andclosure member thereof in a closed position;

FIG. 20 is a cross-sectional view of the end effector and closure memberof FIG. 19, taken along line 20-20 in FIG. 19;

FIG. 21 is a side elevational view of the end effector and portion ofinterchangeable surgical shaft assembly of FIG. 19, with the anvil andclosure member thereof in an over-closed position;

FIG. 22 is a cross-sectional view of the end effector and closure memberof FIG. 21, taken along line 22-22 in FIG. 21;

FIG. 23 is an end view of another distal closure member embodiment;

FIG. 24 is a side elevational view of another end effector and portionof another interchangeable surgical shaft assembly, with an anvil and aclosure member thereof in an open position;

FIG. 25 is a cross-sectional view of the end effector and closure memberof FIG. 24, taken along line 25-25 in FIG. 24;

FIG. 26 is a side elevational view of the end effector andinterchangeable surgical shaft assembly of FIG. 24, with the anvil andclosure member thereof in a closed position;

FIG. 27 is a cross-sectional view of the end effector and closure memberof FIG. 26, taken along line 27-27 in FIG. 26;

FIG. 28 is a side elevational view of the end effector andinterchangeable surgical shaft assembly of FIG. 24, with the anvil andclosure member thereof in an over-closed position;

FIG. 29 is a cross-sectional view of the end effector and closure memberof FIG. 28, taken along line 29-29 in FIG. 28;

FIG. 30 is an end view of another closure member embodiment;

FIG. 31 is a side elevational view of another end effector and portionof another interchangeable surgical shaft assembly, with an anvil and aclosure member thereof in a closed position;

FIG. 32 is another side elevational view of the end effector of theinterchangeable surgical shaft assembly of FIG. 31, with the anvil andclosure member thereof in an “over-closed” position;

FIG. 33 is an enlarged side elevational view of a portion of the endeffector and closure member of FIG. 31, with the anvil in the closedposition;

FIG. 34 is another enlarged side elevational view of a portion of theend effector and closure member of FIG. 32, with the anvil in theover-closed position;

FIG. 35 is a side elevational view of another end effector and portionof another interchangeable surgical shaft assembly, with an anvil and aclosure member thereof in a closed position;

FIG. 36 is an enlarged side elevational view of a portion of the endeffector and closure member of FIG. 35, with the anvil in the closedposition;

FIG. 37 is another side elevational view of the end effector of theinterchangeable surgical shaft assembly of FIG. 35, with the anvil andclosure member thereof in an over-closed position;

FIG. 38 is another enlarged side elevational view of a portion of theend effector and closure member of FIG. 37, with the anvil in theover-closed position;

FIG. 39 is a perspective view of a previous surgical staple cartridgeconfigured to form flexible lines of surgical staples;

FIG. 40 is a top view of lines of surgical staples formed in tissue bythe surgical staple cartridge of FIG. 39;

FIG. 41 is a side elevational view of a previous surgical stapleembodiment;

FIG. 42 is a side elevational view of another previous surgical stapleembodiment;

FIG. 43 is a cross-sectional view of a previous anvil;

FIG. 44 is a photograph taken with a scanning electron microscope of across-section through a welded joint of the previous anvil of FIG. 43;

FIG. 45 is a cross-sectional view of a portion of the previous anvil ofFIGS. 61 and 62 prior to the formation of staple-forming pocketstherein;

FIG. 46 is another cross-sectional view of the previous anvil of FIG. 45after a staple-forming pocket has been coined therein;

FIG. 47 is a photograph taken with a scanning electron microscope of across-section through the previous anvil of FIG. 43;

FIG. 48 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 43;

FIG. 49 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 43;

FIG. 50 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 43;

FIG. 51 is another photograph taken with a scanning electron microscopeof a cross-section of a portion of the previous anvil of FIG. 43;

FIG. 52 is another photograph taken with a scanning electron microscopeof a portion of a staple-forming undersurface of the previous anvil ofFIG. 43;

FIG. 53 is another photograph taken with a scanning electron microscopeof a portion of a staple-forming pocket of the previous anvil of FIG.52;

FIG. 54 is another photograph taken with a scanning electron microscopeof a portion of a bottom surface of the staple-forming pocket of FIG.53;

FIG. 55 is a diagram of a method for forming a surgical stapler anvil;

FIG. 56 is a cross-sectional view of a portion of another anvil that isformed using the method of FIG. 55;

FIG. 57 is another cross-sectional view of a portion of a completedanvil that is formed using the method of FIG. 55;

FIG. 58 is a cross-sectional view of a staple-forming pocket of theanvil of FIG. 56, prior to an application of a coining action;

FIG. 59 is another cross-sectional view of the staple-forming pocket ofFIG. 58 after the application of a coining action thereto;

FIG. 60 is a diagram of another method for forming a surgical stapleranvil;

FIG. 61 is a cross-sectional view of a staple-forming pocket of anotheranvil that is formed using the method of FIG. 60 prior to an applicationof a coining action thereto;

FIG. 62 is a top view of the staple-forming pocket of FIG. 61;

FIG. 63 is another cross-sectional view of the staple-forming pocket ofFIG. 61 after an application of a coining action thereto;

FIG. 64 is a top view of the staple-forming pocket of FIG. 63;

FIG. 65 is a diagram of another method for forming a surgical stapleranvil;

FIG. 66 is a diagram of another method for forming a surgical stapleranvil;

FIG. 67 is a diagram of another method for forming a surgical stapleranvil;

FIG. 68 is a diagram of another method for forming a surgical stapleranvil;

FIG. 69 is a diagram of another method for forming a surgical stapleranvil;

FIG. 70 is a diagram of another method for forming a surgical stapleranvil;

FIG. 71 is a diagram of another method for forming a surgical stapleranvil; and

FIG. 72 is a diagram of another method for forming a surgical stapleranvil.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. ______, entitled METHOD FOR FABRICATINGSURGICAL STAPLER ANVILS, Attorney Docket No. END8577USNP/180088M;

U.S. patent application Ser. No. ______, entitled REINFORCED DEFORMABLEANVIL TIP FOR SURGICAL STAPLER ANVIL, Attorney Docket No.END8578USNP/180393;

U.S. patent application Ser. No. ______, entitled SURGICAL STAPLERANVILS WITH STAPLE DIRECTING PROTRUSIONS AND TISSUE STABILITY FEATURES,Attorney Docket No. END8579USNP/180089;

U.S. patent application Ser. No. ______, entitled SURGICAL STAPLINGDEVICES WITH IMPROVED CLOSURE MEMBERS, Attorney Docket No.END8581USNP/180091;

U.S. patent application Ser. No. ______, entitled SURGICAL STAPLERANVILS WITH TISSUE STOP FEATURES CONFIGURED TO AVOID TISSUE PINCH,Attorney Docket No. END8582USNP/18009;

U.S. patent application Ser. No. ______, entitled METHOD FOR OPERATING APOWERED ARTICULATABLE SURGICAL INSTRUMENT, Attorney Docket No.END8583USNP/180093M;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSWITH PROGRESSIVE JAW CLOSURE ARRANGEMENTS, Attorney Docket No.END8584USNP/180094;

U.S. patent application Ser. No. ______, entitled POWERED SURGICALINSTRUMENTS WITH CLUTCHING ARRANGEMENTS TO CONVERT LINEAR DRIVE MOTIONSTO ROTARY DRIVE MOTIONS, Attorney Docket No. END8585USNP/180095;

U.S. patent application Ser. No. ______, entitled POWERED ARTICULATABLESURGICAL INSTRUMENTS WITH CLUTCHING AND LOCKING ARRANGEMENTS FOR LINKINGAN ARTICULATION DRIVE SYSTEM TO A FIRING DRIVE SYSTEM, Attorney DocketNo. END8586USNP/180096;

U.S. patent application Ser. No. ______, entitled ARTICULATABLE MOTORPOWERED SURGICAL INSTRUMENTS WITH DEDICATED ARTICULATION MOTORARRANGEMENTS, Attorney Docket No. END8587USNP/180097;

U.S. patent application Ser. No. ______, entitled SWITCHING ARRANGEMENTSFOR MOTOR POWERED ARTICULATABLE SURGICAL INSTRUMENTS, Attorney DocketNo. END8588USNP/180098; and

U.S. Design patent application Ser. No. ______, entitled SURGICALSTAPLER ANVILS, Attorney Docket No. END8581USDP/180099D.

Applicant of the present application owns the following U.S. PatentApplications and U.S. Patents that are each herein incorporated byreference in their respective entireties:

U.S. patent application Ser. No. 15/386,185, entitled SURGICAL STAPLINGINSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF, U.S. PatentApplication Publication No. 2018-0168642;

U.S. patent application Ser. No. 15/386,230, entitled ARTICULATABLESURGICAL STAPLING INSTRUMENTS, U.S. Patent Application Publication No.2018-0168649;

U.S. patent application Ser. No. 15/386,221, entitled LOCKOUTARRANGEMENTS FOR SURGICAL END EFFECTORS, U.S. Patent ApplicationPublication No. 2018-01686;

U.S. patent application Ser. No. 15/386,209, entitled SURGICAL ENDEFFECTORS AND FIRING MEMBERS THEREOF, U.S. Patent ApplicationPublication No. 2018-0168645;

U.S. patent application Ser. No. 15/386,198, entitled LOCKOUTARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL ASSEMBLIES,U.S. Patent Application Publication No. 2018-0168644;

U.S. patent application Ser. No. 15/386,240, entitled SURGICAL ENDEFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR, U.S. Patent ApplicationPublication No. 2018-0168651.

U.S. patent application Ser. No. 15/385,939, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN, U.S. PatentApplication Publication No. 2018-0168629;

U.S. patent application Ser. No. 15/385,941, entitled SURGICAL TOOLASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN CLOSURESYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND ARTICULATION ANDFIRING SYSTEMS, U.S. Patent Application Publication No. 2018-0168630;

U.S. patent application Ser. No. 15/385,943, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS, U.S. Patent ApplicationPublication No. 2018-0168631;

U.S. patent application Ser. No. 15/385,950, entitled SURGICAL TOOLASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES, U.S. PatentApplication Publication No. 2018-0168635;

U.S. patent application Ser. No. 15/385,945, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN; U.S. PatentApplication Publication No. 2018-0168632;

U.S. patent application Ser. No. 15/385,946, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS, U.S. Patent ApplicationPublication No. 2018-0168633;

U.S. patent application Ser. No. 15/385,951, entitled SURGICALINSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW OPENINGDISTANCE, U.S. Patent Application Publication No. 2018-0168636;

U.S. patent application Ser. No. 15/385,953, entitled METHODS OFSTAPLING TISSUE, U.S. Patent Application Publication No. 2018-0168637;

U.S. patent application Ser. No. 15/385,954, entitled FIRING MEMBERSWITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL END EFFECTORS,U.S. Patent Application Publication No. 2018-0168638;

U.S. patent application Ser. No. 15/385,955, entitled SURGICAL ENDEFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS, U.S. PatentApplication Publication No. 2018-0168639;

U.S. patent application Ser. No. 15/385,948, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS, U.S. Patent ApplicationPublication No. 2018-0168584;

U.S. patent application Ser. No. 15/385,956, entitled SURGICALINSTRUMENTS WITH POSITIVE JAW OPENING FEATURES, U.S. Patent ApplicationPublication No. 2018-0168640;

U.S. patent application Ser. No. 15/385,958, entitled SURGICALINSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING SYSTEMACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT, U.S. PatentApplication Publication No. 2018-0168641;

U.S. patent application Ser. No. 15/385,947, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN, U.S. PatentApplication Publication No. 2018-0168634;

U.S. patent application Ser. No. 15/385,896, entitled METHOD FORRESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT, U.S. Patent ApplicationPublication No. 2018-0168597;

U.S. patent application Ser. No. 15/385,898, entitled STAPLE-FORMINGPOCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF STAPLES, U.S.Patent Application Publication No. 2018-0168599;

U.S. patent application Ser. No. 15/385,899, entitled SURGICALINSTRUMENT COMPRISING IMPROVED JAW CONTROL, U.S. Patent ApplicationPublication No. 2018-0168600;

U.S. patent application Ser. No. 15/385,901, entitled STAPLE CARTRIDGEAND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS DEFINED THEREIN, U.S.Patent Application Publication No. 2018-0168602;

U.S. patent application Ser. No. 15/385,902, entitled SURGICALINSTRUMENT COMPRISING A CUTTING MEMBER, U.S. Patent ApplicationPublication No. 2018-0168603;

U.S. patent application Ser. No. 15/385,904, entitled STAPLE FIRINGMEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT CARTRIDGE LOCKOUT,U.S. Patent Application Publication No. 2018-0168605;

U.S. patent application Ser. No. 15/385,905, entitled FIRING ASSEMBLYCOMPRISING A LOCKOUT, U.S. Patent Application Publication No.2018-0168606;

U.S. patent application Ser. No. 15/385,907, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A FIRINGASSEMBLY LOCKOUT, U.S. Patent Application Publication No. 2018-0168608;

U.S. patent application Ser. No. 15/385,908, entitled FIRING ASSEMBLYCOMPRISING A FUSE, U.S. Patent Application Publication No. 2018-0168609;

U.S. patent application Ser. No. 15/385,909, entitled FIRING ASSEMBLYCOMPRISING A MULTIPLE FAILED-STATE FUSE, U.S. Patent ApplicationPublication No. 2018-0168610;

U.S. patent application Ser. No. 15/385,920, entitled STAPLE-FORMINGPOCKET ARRANGEMENTS, U.S. Patent Application Publication No.2018-0168620;

U.S. patent application Ser. No. 15/385,913, entitled ANVIL ARRANGEMENTSFOR SURGICAL STAPLERS, U.S. Patent Application Publication No.2018-0168614;

U.S. patent application Ser. No. 15/385,914, entitled METHOD OFDEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES WITH THESAME SURGICAL STAPLING INSTRUMENT, U.S. Patent Application PublicationNo. 2018-0168615;

U.S. patent application Ser. No. 15/385,893, entitled BILATERALLYASYMMETRIC STAPLE-FORMING POCKET PAIRS, U.S. Patent ApplicationPublication No. 2018-0168594;

U.S. patent application Ser. No. 15/385,929, entitled CLOSURE MEMBERSWITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS WITH SEPARATE ANDDISTINCT CLOSURE AND FIRING SYSTEMS, U.S. Patent Application PublicationNo. 2018-0168626;

U.S. patent application Ser. No. 15/385,911, entitled SURGICAL STAPLERSWITH INDEPENDENTLY ACTUATABLE CLOSING AND FIRING SYSTEMS, U.S. PatentApplication Publication No. 2018-0168612;

U.S. patent application Ser. No. 15/385,927, entitled SURGICAL STAPLINGINSTRUMENTS WITH SMART STAPLE CARTRIDGES, U.S. Patent ApplicationPublication No. 2018-0168625;

U.S. patent application Ser. No. 15/385,917, entitled STAPLE CARTRIDGECOMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS, U.S. PatentApplication Publication No. 2018-0168617;

U.S. patent application Ser. No. 15/385,900, entitled STAPLE-FORMINGPOCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND POCKET SIDEWALLS,U.S. Patent Application Publication No. 2018-0168601;

U.S. patent application Ser. No. 15/385,931, entitled NO-CARTRIDGE ANDSPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR SURGICAL STAPLERS, U.S. PatentApplication Publication No. 2018-0168627;

U.S. patent application Ser. No. 15/385,915, entitled FIRING MEMBER PINANGLE, U.S. Patent Application Publication No. 2018-0168616;

U.S. patent application Ser. No. 15/385,897, entitled STAPLE-FORMINGPOCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE GROOVES, U.S.Patent Application Publication No. 2018-0168598;

U.S. patent application Ser. No. 15/385,922, entitled SURGICALINSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES, U.S. Patent ApplicationPublication No. 2018-0168622;

U.S. patent application Ser. No. 15/385,924, entitled SURGICALINSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS, U.S. Patent ApplicationPublication No. 2018-0168624;

U.S. patent application Ser. No. 15/385,910, entitled ANVIL HAVING AKNIFE SLOT WIDTH, U.S. Patent Application Publication No. 2018-0168611;

U.S. patent application Ser. No. 15/385,903, entitled CLOSURE MEMBERARRANGEMENTS FOR SURGICAL INSTRUMENTS, U.S. Patent ApplicationPublication No. 2018-0168604;

U.S. patent application Ser. No. 15/385,906, entitled FIRING MEMBER PINCONFIGURATIONS, U.S. Patent Application Publication No. 2018-0168607;

U.S. patent application Ser. No. 15/386,188, entitled STEPPED STAPLECARTRIDGE WITH ASYMMETRICAL STAPLES, U.S. Patent Application PublicationNo. 2018-0168585;

U.S. patent application Ser. No. 15/386,192, entitled STEPPED STAPLECARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES, U.S. PatentApplication Publication No. 2018-0168643;

U.S. patent application Ser. No. 15/386,206, entitled STAPLE CARTRIDGEWITH DEFORMABLE DRIVER RETENTION FEATURES, U.S. Patent ApplicationPublication No. 2018-0168586;

U.S. patent application Ser. No. 15/386,226, entitled DURABILITYFEATURES FOR END EFFECTORS AND FIRING ASSEMBLIES OF SURGICAL STAPLINGINSTRUMENTS, U.S. Patent Application Publication No. 2018-0168648;

U.S. patent application Ser. No. 15/386,222, entitled SURGICAL STAPLINGINSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING FEATURES, U.S.Patent Application Publication No. 2018-0168647;

U.S. patent application Ser. No. 15/386,236, entitled CONNECTIONPORTIONS FOR DEPOSABLE LOADING UNITS FOR SURGICAL STAPLING INSTRUMENTS,U.S. Patent Application Publication No. 2018-0168650;

U.S. patent application Ser. No. 15/385,887, entitled METHOD FORATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND, ALTERNATIVELY,TO A SURGICAL ROBOT, U.S. Patent Application Publication No.2018-0168589;

U.S. patent application Ser. No. 15/385,889, entitled SHAFT ASSEMBLYCOMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR USE WITH AMOTORIZED SURGICAL INSTRUMENT SYSTEM, U.S. Patent ApplicationPublication No. 2018-0168590;

U.S. patent application Ser. No. 15/385,890, entitled SHAFT ASSEMBLYCOMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE SYSTEMS, U.S. PatentApplication Publication No. 2018-0168591;

U.S. patent application Ser. No. 15/385,891, entitled SHAFT ASSEMBLYCOMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A ROTARY FIRINGMEMBER TO TWO DIFFERENT SYSTEMS, U.S. Patent Application Publication No.2018-0168592;

U.S. patent application Ser. No. 15/385,892, entitled SURGICAL SYSTEMCOMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION STATE TOARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM, U.S. PatentApplication Publication No. 2018-0168593;

U.S. patent application Ser. No. 15/385,894, entitled SHAFT ASSEMBLYCOMPRISING A LOCKOUT, U.S. Patent Application Publication No.2018-0168595;

U.S. patent application Ser. No. 15/385,895, entitled SHAFT ASSEMBLYCOMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS, U.S. PatentApplication Publication No. 2018-0168596;

U.S. patent application Ser. No. 15/385,916, entitled SURGICAL STAPLINGSYSTEMS, U.S. Patent Application Publication No. 2018-0168575;

U.S. patent application Ser. No. 15/385,918, entitled SURGICAL STAPLINGSYSTEMS, U.S. Patent Application Publication No. 2018-0168618;

U.S. patent application Ser. No. 15/385,919, entitled SURGICAL STAPLINGSYSTEMS, U.S. Patent Application Publication No. 2018-0168619;

U.S. patent application Ser. No. 15/385,921, entitled SURGICAL STAPLECARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED TO DISENGAGE FIRINGMEMBER LOCKOUT FEATURES, U.S. Patent Application Publication No.2018-0168621;

U.S. patent application Ser. No. 15/385,923, entitled SURGICAL STAPLINGSYSTEMS, U.S. Patent Application Publication No. 2018-0168623;

U.S. patent application Ser. No. 15/385,925, entitled JAW ACTUATED LOCKARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A FIRING MEMBER IN A SURGICALEND EFFECTOR UNLESS AN UNFIRED CARTRIDGE IS INSTALLED IN THE ENDEFFECTOR, U.S. Patent Application Publication No. 2018-0168576;

U.S. patent application Ser. No. 15/385,926, entitled AXIALLY MOVABLECLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS TO JAWS OFSURGICAL INSTRUMENTS, U.S. Patent Application Publication No.2018-0168577;

U.S. patent application Ser. No. 15/385,928, entitled PROTECTIVE COVERARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW AND ACTUATORSHAFT OF A SURGICAL INSTRUMENT, U.S. Patent Application Publication No.2018-0168578;

U.S. patent application Ser. No. 15/385,930, entitled SURGICAL ENDEFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR OPENING ANDCLOSING END EFFECTOR JAWS, U.S. Patent Application Publication No.2018-0168579;

U.S. patent application Ser. No. 15/385,932, entitled ARTICULATABLESURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT ARRANGEMENT, U.S. PatentApplication Publication No. 2018-0168628;

U.S. patent application Ser. No. 15/385,933, entitled ARTICULATABLESURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE LINKAGE DISTAL OF ANARTICULATION LOCK, U.S. Patent Application Publication No. 2018-0168580;

U.S. patent application Ser. No. 15/385,934, entitled ARTICULATION LOCKARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN ARTICULATED POSITION INRESPONSE TO ACTUATION OF A JAW CLOSURE SYSTEM, U.S. Patent ApplicationPublication No. 2018-0168581;

U.S. patent application Ser. No. 15/385,935, entitled LATERALLYACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR OFA SURGICAL INSTRUMENT IN AN ARTICULATED CONFIGURATION, U.S. PatentApplication Publication No. 2018-0168582;

U.S. patent application Ser. No. 15/385,936, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH ARTICULATION STROKE AMPLIFICATION FEATURES,U.S. Patent Application Publication No., U.S. Patent ApplicationPublication No. 2018-0168583;

U.S. patent application Ser. No. 14/318,996, entitled FASTENERCARTRIDGES INCLUDING EXTENSIONS HAVING DIFFERENT CONFIGURATIONS, U.S.Patent Application Publication No. 2015-0297228;

U.S. patent application Ser. No. 14/319,006, entitled FASTENER CARTRIDGECOMPRISING FASTENER CAVITIES INCLUDING FASTENER CONTROL FEATURES, NowU.S. Pat. No. 10,010,324;

U.S. patent application Ser. No. 14/318,991, entitled SURGICAL FASTENERCARTRIDGES WITH DRIVER STABILIZING ARRANGEMENTS, now U.S. Pat. No.9,833,241;

U.S. patent application Ser. No. 14/319,004, entitled SURGICAL ENDEFFECTORS WITH FIRING ELEMENT MONITORING ARRANGEMENTS, now U.S. Pat. No.9,844,369;

U.S. patent application Ser. No. 14/319,008, entitled FASTENER CARTRIDGECOMPRISING NON-UNIFORM FASTENERS, U.S. Patent Application PublicationNo. 2015-0297232;

U.S. patent application Ser. No. 14/318,997, entitled FASTENER CARTRIDGECOMPRISING DEPLOYABLE TISSUE ENGAGING MEMBERS, U.S. Patent ApplicationPublication No. 2015-0297229;

U.S. patent application Ser. No. 14/319,002, entitled FASTENER CARTRIDGECOMPRISING TISSUE CONTROL FEATURES, now U.S. Pat. No. 9,877,721;

U.S. patent application Ser. No. 14/319,013, entitled FASTENER CARTRIDGEASSEMBLIES AND STAPLE RETAINER COVER ARRANGEMENTS, U.S. PatentApplication Publication No. 2015-0297233; and

U.S. patent application Ser. No. 14/319,016, entitled FASTENER CARTRIDGEINCLUDING A LAYER ATTACHED THERETO, U.S. Patent Application PublicationNo. 2015-0297235.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/191,775, entitled STAPLE CARTRIDGECOMPRISING WIRE STAPLES AND STAMPED STAPLES;

U.S. patent application Ser. No. 15/191,807, entitled STAPLING SYSTEMFOR USE WITH WIRE STAPLES AND STAMPED STAPLES;

U.S. patent application Ser. No. 15/191,834, entitled STAMPED STAPLESAND STAPLE CARTRIDGES USING THE SAME;

U.S. patent application Ser. No. 15/191,788, entitled STAPLE CARTRIDGECOMPRISING OVERDRIVEN STAPLES; and

U.S. patent application Ser. No. 15/191,818, entitled STAPLE CARTRIDGECOMPRISING OFFSET LONGITUDINAL STAPLE ROWS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. Design patent application Ser. No. 29/569,218, entitled SURGICALFASTENER;

U.S. Design patent application Ser. No. 29/569,227, entitled SURGICALFASTENER;

U.S. Design patent application Ser. No. 29/569,259, entitled SURGICALFASTENER CARTRIDGE; and

U.S. Design patent application Ser. No. 29/569,264, entitled SURGICALFASTENER CARTRIDGE.

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 15/089,325, entitled METHOD FOROPERATING A SURGICAL STAPLING SYSTEM;

U.S. patent application Ser. No. 15/089,321, entitled MODULAR SURGICALSTAPLING SYSTEM COMPRISING A DISPLAY;

U.S. patent application Ser. No. 15/089,326, entitled SURGICAL STAPLINGSYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD;

U.S. patent application Ser. No. 15/089,263, entitled SURGICALINSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;

U.S. patent application Ser. No. 15/089,262, entitled ROTARY POWEREDSURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT SYSTEM;

U.S. patent application Ser. No. 15/089,277, entitled SURGICAL CUTTINGAND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE MEMBER;

U.S. patent application Ser. No. 15/089,296, entitled INTERCHANGEABLESURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR THAT IS SELECTIVELYROTATABLE ABOUT A SHAFT AXIS;

U.S. patent application Ser. No. 15/089,258, entitled SURGICAL STAPLINGSYSTEM COMPRISING A SHIFTABLE TRANSMISSION;

U.S. patent application Ser. No. 15/089,278, entitled SURGICAL STAPLINGSYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF TISSUE;

U.S. patent application Ser. No. 15/089,284, entitled SURGICAL STAPLINGSYSTEM COMPRISING A CONTOURABLE SHAFT;

U.S. patent application Ser. No. 15/089,295, entitled SURGICAL STAPLINGSYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT;

U.S. patent application Ser. No. 15/089,300, entitled SURGICAL STAPLINGSYSTEM COMPRISING AN UNCLAMPING LOCKOUT;

U.S. patent application Ser. No. 15/089,196, entitled SURGICAL STAPLINGSYSTEM COMPRISING A JAW CLOSURE LOCKOUT;

U.S. patent application Ser. No. 15/089,203, entitled SURGICAL STAPLINGSYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT;

U.S. patent application Ser. No. 15/089,210, entitled SURGICAL STAPLINGSYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT;

U.S. patent application Ser. No. 15/089,324, entitled SURGICALINSTRUMENT COMPRISING A SHIFTING MECHANISM;

U.S. patent application Ser. No. 15/089,335, entitled SURGICAL STAPLINGINSTRUMENT COMPRISING MULTIPLE LOCKOUTS;

U.S. patent application Ser. No. 15/089,339, entitled SURGICAL STAPLINGINSTRUMENT;

U.S. patent application Ser. No. 15/089,253, entitled SURGICAL STAPLINGSYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES HAVING DIFFERENTHEIGHTS;

U.S. patent application Ser. No. 15/089,304, entitled SURGICAL STAPLINGSYSTEM COMPRISING A GROOVED FORMING POCKET;

U.S. patent application Ser. No. 15/089,331, entitled ANVIL MODIFICATIONMEMBERS FOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/089,336, entitled STAPLE CARTRIDGESWITH ATRAUMATIC FEATURES;

U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR STAPLINGSYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT;

U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR STAPLINGSYSTEM COMPRISING ROTARY FIRING SYSTEM; and

U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR STAPLINGSYSTEM COMPRISING LOAD CONTROL.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS FORCOMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 14/984,552, entitled SURGICALINSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entirety:

U.S. patent application Ser. No. 15/019,220, entitled SURGICALINSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END EFFECTOR;

U.S. patent application Ser. No. 15/019,228, entitled SURGICALINSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,196, entitled SURGICALINSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT;

U.S. patent application Ser. No. 15/019,206, entitled SURGICALINSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE RELATIVETO AN ELONGATE SHAFT ASSEMBLY;

U.S. patent application Ser. No. 15/019,215, entitled SURGICALINSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,227, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,235, entitled SURGICALINSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN ARTICULATIONSYSTEMS;

U.S. patent application Ser. No. 15/019,230, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM ARRANGEMENTS; and

U.S. patent application Ser. No. 15/019,245, entitled SURGICALINSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respective entirety:

U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/742,925, entitled SURGICAL ENDEFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS;

U.S. patent application Ser. No. 14/742,941, entitled SURGICAL ENDEFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES;

U.S. patent application Ser. No. 14/742,914, entitled MOVABLE FIRINGBEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 14/742,900, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM STRUCTURES WITH CENTERFIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT;

U.S. patent application Ser. No. 14/742,885, entitled DUAL ARTICULATIONDRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULLARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/640,746, entitled POWERED SURGICALINSTRUMENT, now U.S. Patent Application Publication No. 2016/0256184;

U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE LEVELTHRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS, now U.S.Patent Application Publication No. 2016/02561185;

U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE TISSUECOMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUETYPES, now U.S. Patent Application Publication No. 2016/0256154;

U.S. patent application Ser. No. 14/640,935, entitled OVERLAID MULTISENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUECOMPRESSION, now U.S. Patent Application Publication No. 2016/0256071;

U.S. patent application Ser. No. 14/640,831, entitled MONITORING SPEEDCONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED SURGICALINSTRUMENTS, now U.S. Patent Application Publication No. 2016/0256153;

U.S. patent application Ser. No. 14/640,859, entitled TIME DEPENDENTEVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, ANDVISCOELASTIC ELEMENTS OF MEASURES, now U.S. Patent ApplicationPublication No. 2016/0256187;

U.S. patent application Ser. No. 14/640,817, entitled INTERACTIVEFEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2016/0256186;

U.S. patent application Ser. No. 14/640,844, entitled CONTROL TECHNIQUESAND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROLPROCESSING FROM HANDLE, now U.S. Patent Application Publication No.2016/0256155;

U.S. patent application Ser. No. 14/640,837, entitled SMART SENSORS WITHLOCAL SIGNAL PROCESSING, now U.S. Patent Application Publication No.2016/0256163;

U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FORDETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICALSTAPLER, now U.S. Patent Application Publication No. 2016/0256160;

U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND POWERCOMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT, now U.S. PatentApplication Publication No. 2016/0256162; and

U.S. patent application Ser. No. 14/640,780, entitled SURGICALINSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING, now U.S. PatentApplication Publication No. 2016/0256161.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/633,576, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION, now U.S. PatentApplication Publication No. 2016/0249919;

U.S. patent application Ser. No. 14/633,546, entitled SURGICAL APPARATUSCONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF THE SURGICALAPPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND, now U.S. PatentApplication Publication No. 2016/0249915;

U.S. patent application Ser. No. 14/633,560, entitled SURGICAL CHARGINGSYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES, now U.S.Patent Application Publication No. 2016/0249910;

U.S. patent application Ser. No. 14/633,566, entitled CHARGING SYSTEMTHAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY, now U.S.Patent Application Publication No. 2016/0249918;

U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FORMONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED, now U.S.Patent Application Publication No. 2016/0249916;

U.S. patent application Ser. No. 14/633,542, entitled REINFORCED BATTERYFOR A SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2016/0249908;

U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER FORA SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2016/0249909;

U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE SURGICALINSTRUMENT HANDLE, now U.S. Patent Application Publication No.2016/0249945;

U.S. patent application Ser. No. 14/633,541, entitled MODULAR STAPLINGASSEMBLY, now U.S. Patent Application Publication No. 2016/0249927; and

U.S. patent application Ser. No. 14/633,562, entitled SURGICAL APPARATUSCONFIGURED TO TRACK AN END-OF-LIFE PARAMETER, now U.S. PatentApplication Publication No. 2016/0249917.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/574,478, entitled SURGICALINSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND MEANSFOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER, now U.S. PatentApplication Publication No. 2016/0174977;

U.S. patent application Ser. No. 14/574,483, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS, now U.S. PatentApplication Publication No. 2016/0174969;

U.S. patent application Ser. No. 14/575,139, entitled DRIVE ARRANGEMENTSFOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2016/0174978;

U.S. patent application Ser. No. 14/575,148, entitled LOCKINGARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE SURGICALEND EFFECTORS, now U.S. Patent Application Publication No. 2016/0174976;

U.S. patent application Ser. No. 14/575,130, entitled SURGICALINSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A DISCRETENON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now U.S. PatentApplication Publication No. 2016/0174972;

U.S. patent application Ser. No. 14/575,143, entitled SURGICALINSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS, now U.S. PatentApplication Publication No. 2016/0174983;

U.S. patent application Ser. No. 14/575,117, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAMSUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.2016/0174975;

U.S. patent application Ser. No. 14/575,154, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING BEAMSUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.2016/0174973;

U.S. patent application Ser. No. 14/574,493, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM, now U.S.Patent Application Publication No. 2016/0174970; and

U.S. patent application Ser. No. 14/574,500, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM, now U.S.Patent Application Publication No. 2016/0174971.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION,now U.S. Patent Application Publication No. 2014/0246471;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0246472;

U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2014/0249557;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now U.S. Pat. No.9,358,003;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0246478;

U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,326,767;

U.S. patent application Ser. No. 13/782,481, entitled SENSORSTRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S. Pat.No. 9,468,438;

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODSFOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS, now U.S.Patent Application Publication No. 2014/0246475;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Pat. No.9,398,911; and

U.S. patent application Ser. No. 13/782,536, entitled SURGICALINSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. PatentApplication Publication No. 2014/0263542;

U.S. patent application Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S. Pat.No. 9,332,987;

U.S. patent application Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT, now U.S. PatentApplication Publication No. 2014/0263564;

U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541;

U.S. patent application Ser. No. 13/803,210, entitled SENSORARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS,now U.S. Patent Application Publication No. 2014/0263538;

U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent Application PublicationNo. 2014/0263554;

U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0263565;

U.S. patent application Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,726;

U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAINCONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,727; and

U.S. patent application Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

U.S. patent application Ser. No. 14/200,111, entitled CONTROL SYSTEMSFOR SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No.2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled STERILIZATIONVERIFICATION CIRCUIT, now U.S. Patent Application Publication No.2015/0272581;

U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION OFNUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now U.S. Patent ApplicationPublication No. 2015/0272580;

U.S. patent application Ser. No. 14/226,117, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL, now U.S.Patent Application Publication No. 2015/0272574;

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now U.S. PatentApplication Publication No. 2015/0272579;

U.S. patent application Ser. No. 14/226,093, entitled FEEDBACKALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.Patent Application Publication No. 2015/0272569;

U.S. patent application Ser. No. 14/226,116, entitled SURGICALINSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent ApplicationPublication No. 2015/0272571;

U.S. patent application Ser. No. 14/226,071, entitled SURGICALINSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S. PatentApplication Publication No. 2015/0272578;

U.S. patent application Ser. No. 14/226,097, entitled SURGICALINSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent ApplicationPublication No. 2015/0272570;

U.S. patent application Ser. No. 14/226,126, entitled INTERFACE SYSTEMSFOR USE WITH SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272572;

U.S. patent application Ser. No. 14/226,133, entitled MODULAR SURGICALINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272557;

U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent ApplicationPublication No. 2015/0277471;

U.S. patent application Ser. No. 14/226,076, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION, now U.S.Patent Application Publication No. 2015/0280424;

U.S. patent application Ser. No. 14/226,111, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272583; and

U.S. patent application Ser. No. 14/226,125, entitled SURGICALINSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Patent ApplicationPublication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY ANDSENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent ApplicationPublication No. 2016/0066912;

U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT WITHINTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S. PatentApplication Publication No. 2016/0066914;

U.S. patent application Ser. No. 14/478,908, entitled MONITORING DEVICEDEGRADATION BASED ON COMPONENT EVALUATION, now U.S. Patent ApplicationPublication No. 2016/0066910;

U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE SENSORSWITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR INTERPRETATION,now U.S. Patent Application Publication No. 2016/0066909;

U.S. patent application Ser. No. 14/479,110, entitled POLARITY OF HALLMAGNET TO DETECT MISLOADED CARTRIDGE, now U.S. Patent ApplicationPublication No. 2016/0066915;

U.S. patent application Ser. No. 14/479,098, entitled SMART CARTRIDGEWAKE UP OPERATION AND DATA RETENTION, now U.S. Patent ApplicationPublication No. 2016/0066911;

U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTORCONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent ApplicationPublication No. 2016/0066916; and

U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY OFTISSUE PARAMETER STABILIZATION, now U.S. Patent Application PublicationNo. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVENSURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S. PatentApplication Publication No. 2014/0305987;

U.S. patent application Ser. No. 14/248,581, entitled SURGICALINSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROMTHE SAME ROTATABLE OUTPUT, now U.S. Patent Application Publication No.2014/0305989;

U.S. patent application Ser. No. 14/248,595, entitled SURGICALINSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF THESURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2014/0305988;

U.S. patent application Ser. No. 14/248,588, entitled POWERED LINEARSURGICAL STAPLER, now U.S. Patent Application Publication No.2014/0309666;

U.S. patent application Ser. No. 14/248,591, entitled TRANSMISSIONARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2014/0305991;

U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARYDRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S. PatentApplication Publication No. 2014/0305994;

U.S. patent application Ser. No. 14/248,587, entitled POWERED SURGICALSTAPLER, now U.S. Patent Application Publication No. 2014/0309665;

U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEMDECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. PatentApplication Publication No. 2014/0305990; and

U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, nowU.S. Patent Application Publication No. 2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entirety:

U.S. Provisional Patent Application Ser. No. 61/812,365, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR;

U.S. Provisional Patent Application Ser. No. 61/812,376, entitled LINEARCUTTER WITH POWER;

U.S. Provisional Patent Application Ser. No. 61/812,382, entitled LINEARCUTTER WITH MOTOR AND PISTOL GRIP;

U.S. Provisional Patent Application Ser. No. 61/812,385, entitledSURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTORCONTROL; and

U.S. Provisional Patent Application Ser. No. 61/812,372, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIGS. 1 and 3 depict a motor-driven surgical cutting and fasteninginstrument 1010 that may or may not be reused. In the illustratedembodiment, the instrument 1010 includes a previous housing 1012 thatcomprises a handle 1014 that is configured to be grasped, manipulatedand actuated by the clinician. The housing 1012 is configured foroperable attachment to an interchangeable shaft assembly 1200 that has asurgical end effector 1300 operably coupled thereto that is configuredto perform one or more surgical tasks or procedures. As the presentDetailed Description proceeds, it will be understood that the variousforms of interchangeable shaft assemblies disclosed herein may also beeffectively employed in connection with robotically-controlled surgicalsystems. Thus, the term “housing” may also encompass a housing orsimilar portion of a robotic system that houses or otherwise operablysupports at least one drive system that is configured to generate andapply at least one control motion which could be used to actuate theinterchangeable shaft assemblies disclosed herein and their respectiveequivalents. In addition, various components may be “housed” orcontained in the housing or various components may be “associated with”a housing. In such instances, the components may not be contained withthe housing or supported directly by the housing. The term “frame” mayrefer to a portion of a handheld surgical instrument. The term “frame”may also represent a portion of a robotically controlled surgicalinstrument and/or a portion of the robotic system that may be used tooperably control a surgical instrument. For example, the interchangeableshaft assemblies disclosed herein may be employed with various roboticsystems, instruments, components and methods disclosed in U.S. Pat. No.9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, that is incorporated by reference herein in itsentirety.

The previous housing 1012 depicted in FIG. 1 is shown in connection withan interchangeable shaft assembly 1200 (FIGS. 2, 4 and 5) that includesan end effector 1300 that comprises a surgical cutting and fasteningdevice that is configured to operably support a surgical staplecartridge 4000 therein. The housing 1012 may be configured for use inconnection with interchangeable shaft assemblies that include endeffectors that are adapted to support different sizes and types ofstaple cartridges, have different shaft lengths, sizes, and types, etc.In addition, the housing 1012 may also be effectively employed with avariety of other interchangeable shaft assemblies including thoseassemblies that are configured to apply other motions and forms ofenergy such as, for example, radio frequency (RF) energy, ultrasonicenergy and/or motion to end effector arrangements adapted for use inconnection with various surgical applications and procedures.Furthermore, the end effectors, shaft assemblies, handles, surgicalinstruments, and/or surgical instrument systems can utilize any suitablefastener, or fasteners, to fasten tissue. For instance, a fastenercartridge comprising a plurality of fasteners removably stored thereincan be removably inserted into and/or attached to the end effector of ashaft assembly.

FIG. 1 illustrates the surgical instrument 1010 that includes aninterchangeable shaft assembly 1200 operably coupled to the housing1012. FIG. 2 illustrates the interchangeable shaft assembly 1200detached from the housing 1012 or handle 1014. As can be seen in FIG. 3,the handle 1014 may comprise a pair of interconnectable handle housingsegments 1016 and 1018 that may be interconnected by screws, snapfeatures, adhesive, etc. In the illustrated arrangement, the handlehousing segments 1016, 1018 cooperate to form a pistol grip portion 1019that can be gripped and manipulated by the clinician. As will bediscussed in further detail below, the handle 1014 operably supports aplurality of drive systems therein that are configured to generate andapply various control motions to corresponding portions of theinterchangeable shaft assembly that is operably attached thereto.

Referring now to FIG. 3, the handle 1014 may further include a frame1020 that operably supports a plurality of drive systems. For example,the frame 1020 can operably support a “first” or closure drive system,generally designated as 1030, which may be employed to apply closing andopening motions to the interchangeable shaft assembly 1200 that isoperably attached or coupled thereto. In at least one form, the closuredrive system 1030 may include an actuator in the form of a closuretrigger 1032 that is pivotally supported by the frame 1020. Morespecifically, as illustrated in FIG. 3, the closure trigger 1032 ispivotally coupled to the housing 1014 by a pin 1033. Such arrangementenables the closure trigger 1032 to be manipulated by a clinician suchthat when the clinician grips the pistol grip portion 1019 of the handle1014, the closure trigger 1032 may be easily pivoted from a starting or“unactuated” position to an “actuated” position and more particularly toa fully compressed or fully actuated position. The closure trigger 1032may be biased into the unactuated position by spring or other biasingarrangement (not shown). In various forms, the closure drive system 1030further includes a closure linkage assembly 1034 that is pivotallycoupled to the closure trigger 1032. As can be seen in FIG. 3, theclosure linkage assembly 1034 may include a first closure link 1036 anda second closure link 1038 that are pivotally coupled to the closuretrigger 1032 by a pin 1035. The second closure link 1038 may also bereferred to herein as an “attachment member” and include a transverseattachment pin 1037.

Still referring to FIG. 3, it can be observed that the first closurelink 1036 may have a locking wall or end 1039 thereon that is configuredto cooperate with a closure release assembly 1060 that is pivotallycoupled to the frame 1020. In at least one form, the closure releaseassembly 1060 may comprise a release button assembly 1062 that has adistally protruding locking pawl 1064 formed thereon. The release buttonassembly 1062 may be pivoted in a counterclockwise direction by arelease spring (not shown). As the clinician depresses the closuretrigger 1032 from its unactuated position towards the pistol gripportion 1019 of the handle 1014, the first closure link 1036 pivotsupward to a point wherein the locking pawl 1064 drops into retainingengagement with the locking wall 1039 on the first closure link 1036thereby preventing the closure trigger 1032 from returning to theunactuated position. Thus, the closure release assembly 1060 serves tolock the closure trigger 1032 in the fully actuated position. When theclinician desires to unlock the closure trigger 1032 to permit it to bebiased to the unactuated position, the clinician simply pivots theclosure release button assembly 1062 such that the locking pawl 1064 ismoved out of engagement with the locking wall 1039 on the first closurelink 1036. When the locking pawl 1064 has been moved out of engagementwith the first closure link 1036, the closure trigger 1032 may pivotback to the unactuated position. Other closure trigger locking andrelease arrangements may also be employed.

An arm 1061 may extend from the closure release button 1062. A magneticelement 1063, such as a permanent magnet, for example, may be mounted tothe arm 1061. When the closure release button 1062 is rotated from itsfirst position to its second position, the magnetic element 1063 canmove toward a circuit board 1100. The circuit board 1100 can include atleast one sensor that is configured to detect the movement of themagnetic element 1063. In at least one embodiment, for example, a “HallEffect” sensor (not shown) can be mounted to the bottom surface of thecircuit board 1100. The Hall Effect sensor can be configured to detectchanges in a magnetic field surrounding the Hall Effect sensor caused bythe movement of the magnetic element 1063. The Hall Effect sensor can bein signal communication with a microcontroller, for example, which candetermine whether the closure release button 1062 is in its firstposition, which is associated with the unactuated position of theclosure trigger 1032 and the open configuration of the end effector, itssecond position, which is associated with the actuated position of theclosure trigger 1032 and the closed configuration of the end effector,and/or any position between the first position and the second position.

In at least one form, the handle 1014 and the frame 1020 may operablysupport another drive system referred to herein as a firing drive system1080 that is configured to apply firing motions to correspondingportions of the interchangeable shaft assembly attached thereto. Thefiring drive system may 1080 also be referred to herein as a “seconddrive system”. The firing drive system 1080 may employ an electric motor1082 that is located in the pistol grip portion 1019 of the handle 1014.In various forms, the motor 1082 may be a DC brushed driving motorhaving a maximum rotation of, approximately, 25,000 RPM, for example. Inother arrangements, the motor may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. The motor 1082 may be powered by a power source 1090that in one form may comprise a removable power pack 1092. As can beseen in FIG. 3, for example, the power pack 1092 may comprise a proximalhousing portion 1094 that is configured for attachment to a distalhousing portion 1096. The proximal housing portion 1094 and the distalhousing portion 1096 are configured to operably support a plurality ofbatteries 1098 therein. Batteries 1098 may each comprise, for example, aLithium Ion (“LI”) or other suitable battery. The distal housing portion1096 is configured for removable operable attachment to the circuitboard assembly 1100 which is also operably coupled to the motor 1082. Anumber of batteries 1098 may be connected in series may be used as thepower source for the surgical instrument 1010. In addition, the powersource 1090 may be replaceable and/or rechargeable.

As outlined above with respect to other various forms, the electricmotor 1082 can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly 1084 that is mounted in meshingengagement with a with a set, or rack, of drive teeth 1122 on alongitudinally-movable drive member 1120. In use, a voltage polarityprovided by the power source 1090 can operate the electric motor 1082 ina clockwise direction wherein the voltage polarity applied to theelectric motor by the battery can be reversed in order to operate theelectric motor 1082 in a counter-clockwise direction. When the electricmotor 1082 is rotated in one direction, the drive member 1120 will beaxially driven in the distal direction “DD”. When the motor 82 is drivenin the opposite rotary direction, the drive member 1120 will be axiallydriven in a proximal direction “PD”. The handle 1014 can include aswitch which can be configured to reverse the polarity applied to theelectric motor 1082 by the power source 1090. As with the other formsdescribed herein, the handle 1014 can also include a sensor that isconfigured to detect the position of the drive member 1120 and/or thedirection in which the drive member 1120 is being moved.

Actuation of the motor 1082 can be controlled by a firing trigger 1130that is pivotally supported on the handle 1014. The firing trigger 1130may be pivoted between an unactuated position and an actuated position.The firing trigger 1130 may be biased into the unactuated position by aspring 1132 or other biasing arrangement such that when the clinicianreleases the firing trigger 1130, it may be pivoted or otherwisereturned to the unactuated position by the spring 1132 or biasingarrangement. In at least one form, the firing trigger 1130 can bepositioned “outboard” of the closure trigger 132 as was discussed above.In at least one form, a firing trigger safety button 1134 may bepivotally mounted to the closure trigger 1032 by pin 1035. The safetybutton 1134 may be positioned between the firing trigger 1130 and theclosure trigger 1032 and have a pivot arm 1136 protruding therefrom. SeeFIG. 21. When the closure trigger 1032 is in the unactuated position,the safety button 1134 is contained in the handle 1014 where theclinician cannot readily access it and move it between a safety positionpreventing actuation of the firing trigger 1130 and a firing positionwherein the firing trigger 1130 may be fired. As the clinician depressesthe closure trigger 1032, the safety button 1134 and the firing trigger1130 pivot down wherein they can then be manipulated by the clinician.

As indicated above, in at least one form, the longitudinally movabledrive member 1120 has a rack of teeth 1122 formed thereon for meshingengagement with a corresponding drive gear 1086 of the gear reducerassembly 1084. At least one form also includes a manually-actuatable“bailout” assembly 1140 that is configured to enable the clinician tomanually retract the longitudinally movable drive member 1120 should themotor 1082 become disabled. The bailout assembly 1140 may include alever or bailout handle assembly 1142 that is configured to be manuallypivoted into ratcheting engagement with teeth 1124 also provided in thedrive member 1120. Thus, the clinician can manually retract the drivemember 1120 by using the bailout handle assembly 1142 to ratchet thedrive member 1120 in the proximal direction “PD”. U.S. Pat. No.8,608,045, entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITHMANUALLY RETRACTABLE FIRING SYSTEM, discloses bailout arrangements andother components, arrangements and systems that may also be employedwith the various instruments disclosed herein. U.S. Pat. No. 8,608,045,is hereby incorporated by reference herein in its entirety.

Turning now to FIGS. 2 and 5, the interchangeable shaft assembly 1200includes a surgical end effector 1300 that comprises an elongate channel1310 that is configured to operably support a staple cartridge 4000therein. The end effector 1300 may further include an anvil 2000 that ispivotally supported relative to the elongate channel 1310. Theinterchangeable shaft assembly 1200 may further include an articulationjoint 3020 and an articulation lock 2140 which can be configured toreleasably hold the end effector 1300 in a desired position relative toa shaft axis SA. Examples of various features of at least one form ofthe end effector 1300, the articulation joint 3020 and articulationlocks may be found in U.S. patent application Ser. No. 13/803,086, filedMar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING ANARTICULATION LOCK. The entire disclosure of U.S. Patent Application Ser.No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLE SURGICALINSTRUMENT COMPRISING AN ARTICULATION LOCK is hereby incorporated byreference herein. As can be seen in FIG. 4, the interchangeable shaftassembly 1200 can further include a proximal housing or nozzle 1201comprised of nozzle portions 1202 and 1203.

The interchangeable shaft assembly 1200 can further include a closuresystem or closure member assembly 3000 which can be utilized to closeand/or open the anvil 2000 of the end effector 1300. The shaft assembly1200 can include a spine 1210 that is configured to, one, slidablysupport a firing member therein and, two, slidably support the closuremember assembly 3000 which extends around the spine 1210. As can be seenin FIG. 5, a distal end 1211 of spine 1210 terminates in an upper lugmount feature 1270 and in a lower lug mount feature 1280. The upper lugmount feature 1270 is formed with a lug slot 1272 therein that isadapted to mountingly support an upper mounting link 1274 therein.Similarly, the lower lug mount feature 1280 is formed with a lug slot1282 therein that is adapted to mountingly support a lower mounting link1284 therein. The upper mounting link 1274 includes a pivot socket 1276therein that is adapted to rotatably receive therein a pivot pin 1292that is formed on a channel cap or anvil retainer 1290 that is attachedto a proximal end portion 1312 of the elongate channel 1310. The lowermounting link 1284 includes lower pivot pin 1286 that adapted to bereceived within a pivot hole 1314 formed in the proximal end portion1312 of the elongate channel 1310. See FIG. 5. The lower pivot pin 1286is vertically aligned with the pivot socket 1276 to define anarticulation axis AA about which the surgical end effector 1300 mayarticulate relative to the shaft axis SA. See FIG. 2.

In the illustrated example, the surgical end effector 1300 isselectively articulatable about the articulation axis AA by anarticulation system 2100. In one form, the articulation system 2100includes proximal articulation driver 2102 that is pivotally coupled toan articulation link 2120. As can be most particularly seen in FIG. 5,an offset attachment lug 2114 is formed on a distal end 2112 of theproximal articulation driver 2102. A pivot hole 2116 is formed in theoffset attachment lug 2114 and is configured to pivotally receivetherein a proximal link pin 2124 formed on the proximal end 2122 of thearticulation link 3020. A distal end 2126 of the articulation link 2120includes a pivot hole 2128 that is configured to pivotally receivetherein a channel pin 1317 formed on the proximal end portion 1312 ofthe elongate channel 1310. Thus, axial movement of proximal articulationdriver 2102 will thereby apply articulation motions to the elongatechannel 1310 to thereby cause the surgical end effector 1300 toarticulate about the articulation axis AA relative to the spine assembly1210. Further details concerning the construction and operation of thearticulation system 2100 may be found in various references incorporatedby reference herein including U.S. patent application Ser. No.15/635,631, filed Jun. 28, 2017, entitled SURGICAL INSTRUMENT WITHAXIALLY MOVABLE CLOSURE MEMBER, the entire disclosure of which is herebyincorporated by reference herein. In various circumstances, the proximalarticulation driver 2102 can be held in position by an articulation lock2140 when the proximal articulation driver 2102 is not being moved inthe proximal or distal directions. Additional details regarding anexample of an articulation lock 2140 may be found in U.S. patentapplication Ser. No. 15/635,631 as well as in other referencesincorporated by reference herein.

In various circumstances, the spine 1210 can comprise a proximal end1211 which is rotatably supported in a chassis 1240. In one arrangement,for example, the proximal end 1211 of the spine 1210 has a thread 1214formed thereon for threaded attachment to a spine bearing 1216configured to be supported within the chassis 1240. See FIG. 4. Such anarrangement facilitates rotatable attachment of the spine 1210 to thechassis 1240 such that the spine 1210 may be selectively rotated about ashaft axis SA relative to the chassis 1240.

Referring primarily to FIG. 4, the interchangeable shaft assembly 1200includes a closure shuttle 1250 that is slidably supported within thechassis 1240 such that it may be axially moved relative thereto. Theclosure shuttle 1250 includes a pair of proximally-protruding hooks 1252that are configured for attachment to the attachment pin 1037 (FIGS. 2and 3) that is attached to the second closure link 1038 as will bediscussed in further detail below. In at least one example, the closuremember assembly 3000 comprises a proximal closure member segment 3010that has a proximal end 3012 that is coupled to the closure shuttle 1250for relative rotation thereto. For example, a U shaped connector 1263 isinserted into an annular slot 3014 in the proximal end 3012 of theproximal closure member segment 3010 and is retained within verticalslots 1253 in the closure shuttle 1250. Such an arrangement serves toattach the proximal closure tube segment 3010 to the closure shuttle1250 for axial travel therewith while enabling the proximal closure tubesegment 3010 to rotate relative to the closure shuttle 1250 about theshaft axis SA. A closure spring 1268 is journaled on the proximalclosure tube segment 3010 and serves to bias the proximal closure tubesegment 3010 in the proximal direction “PD” which can serve to pivot theclosure trigger 1032 into the unactuated position when the shaftassembly is operably coupled to the handle 1014.

In at least one form, the interchangeable shaft assembly 1200 mayfurther include an articulation joint 3020. Other interchangeable shaftassemblies, however, may not be capable of articulation. As can be seenin FIG. 5, for example, a distal closure member or distal closure tubesegment 3030 is coupled to the distal end of the proximal closure memberor proximal closure tube segment 3010. The articulation joint 3020includes a double pivot closure sleeve assembly 3022. According tovarious forms, the double pivot closure sleeve assembly 3022 includes anend effector closure tube 3050 having upper and lower distallyprojecting tangs 3052, 3054. An upper double pivot link 3056 includesupwardly projecting distal and proximal pivot pins that engagerespectively an upper distal pin hole in the upper proximally projectingtang 3052 and an upper proximal pin hole in an upper distally projectingtang 3032 on the distal closure tube segment 3030. A lower double pivotlink 3058 includes upwardly projecting distal and proximal pivot pinsthat engage respectively a lower distal pin hole in the lower proximallyprojecting tang 3054 and a lower proximal pin hole in the lower distallyprojecting tang 3034. See FIGS. 4 and 5. As will be discussed in furtherdetail below, the closure tube assembly 3000 is translated distally(direction “DD”) to close the anvil 2000, for example, in response tothe actuation of the closure trigger 1032. The anvil 2000 is opened byproximally translating the closure tube assembly 3000 which causes theend effector closure sleeve to interact with the anvil 2000 and pivot itto an open position.

As was also indicated above, the interchangeable shaft assembly 1200further includes a firing member 1900 that is supported for axial travelwithin the shaft spine 1210. The firing member includes an intermediatefiring shaft portion 1222 that is configured for attachment to a distalcutting portion or knife bar 1910. The intermediate firing shaft portion1222 may include a longitudinal slot 1223 in the distal end thereofwhich can be configured to receive a tab 1912 on the proximal end of thedistal knife bar 1910. The longitudinal slot 1223 and the proximal endtab 1912 can be sized and configured to permit relative movementtherebetween and can comprise a slip joint. The slip joint 1914 canpermit the intermediate firing shaft portion 1222 of the firing drive tobe moved to articulate the end effector 1300 without moving, or at leastsubstantially moving, the knife bar 1910. Once the end effector 1300 hasbeen suitably oriented, the intermediate firing shaft portion 1222 canbe advanced distally until a proximal sidewall of the longitudinal slot1223 comes into contact with the tab 1912 in order to advance the knifebar 1910 and fire the staple cartridge 4000 positioned within thechannel 1310. The knife bar 1910 includes a knife portion 1920 thatincludes a blade or tissue cutting edge 1922 and includes an upper anvilengagement tab 1924 and lower channel engagement tabs 1926. Variousfiring member configurations and operations are disclosed in variousother references incorporated herein by reference.

As can be seen in FIG. 4, the shaft assembly 1200 further includes aswitch drum 1500 that is rotatably received on the closure tube 1260.The switch drum 1500 comprises a hollow shaft segment 1502 that has ashaft boss formed thereon for receive an outwardly protruding actuationpin therein. In various circumstances, the actuation pin extends througha longitudinal slot provided in the lock sleeve to facilitate axialmovement of the lock sleeve when it is engaged with the articulationdriver. A rotary torsion spring 1420 is configured to engage the boss onthe switch drum 1500 and a portion of the nozzle housing 1203 to apply abiasing force to the switch drum 1500. The switch drum 1500 can furthercomprise at least partially circumferential openings 1506 definedtherein which can be configured to receive circumferential mountsextending from the nozzle halves 1202, 1203 and permit relativerotation, but not translation, between the switch drum 1500 and theproximal nozzle 1201. The mounts also extend through openings 3011 inthe proximal closure tube segment 3010 to be seated in recesses 1219 inthe spine shaft 1210. Rotation of the switch drum 1500 about the shaftaxis SA will ultimately result in the rotation of the actuation pin andthe lock sleeve between its engaged and disengaged positions. In onearrangement, the rotation of the switch drum 1500 may be linked to theaxial advancement of the closure tube or closure member. Thus, inessence, actuation of the closure system may operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentapplication Ser. No. 13/803,086 and U.S. Pat. No. 9,913,642, entitledSURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM, the entire disclosuresof each being hereby incorporated by reference herein. For example, whenthe closure tube is in its proximal-most position corresponding to a“jaws open” position, the closure tube segment 3010 will have positionedthe switch drum 1500 so as to link the articulation system with thefiring drive system. When, the closure tube has been moved to its distalposition corresponding to a “jaws closed” position, the closure tube hasrotated the switch drum 1500 to a position wherein the articulationsystem is delinked from the firing drive system.

As also illustrated in FIG. 4, the shaft assembly 1200 can comprise aslip ring assembly 1600 which can be configured to conduct electricalpower to and/or from the end effector 1300 and/or communicate signals toand/or from the end effector 1300, for example. The slip ring assembly1600 can comprise a proximal connector flange 1604 that is mounted to achassis flange 1242 that extends from the chassis 1240 and a distalconnector flange that is positioned within a slot defined in the shafthousings. The proximal connector flange 1604 can comprise a first faceand the distal connector flange can comprise a second face which ispositioned adjacent to and movable relative to the first face. Thedistal connector flange can rotate relative to the proximal connectorflange 1604 about the shaft axis SA. The proximal connector flange 1604can comprise a plurality of concentric, or at least substantiallyconcentric, conductors defined in the first face thereof. A connectorcan be mounted on the proximal side of the connector flange and may havea plurality of contacts wherein each contact corresponds to and is inelectrical contact with one of the conductors. Such an arrangementpermits relative rotation between the proximal connector flange 1604 andthe distal connector flange while maintaining electrical contacttherebetween. The proximal connector flange 1604 can include anelectrical connector 1606 which can place the conductors in signalcommunication with a shaft circuit board 1610 mounted to the shaftchassis 1240, for example. In at least one instance, a wiring harnesscomprising a plurality of conductors can extend between the electricalconnector 1606 and the shaft circuit board 1610. The electricalconnector 1606 may extend proximally through a connector opening 1243defined in the chassis mounting flange 1242. See FIG. 4. Further detailsregarding slip ring assembly 1600 may be found in U.S. patentapplication Ser. No. 13/803,086, U.S. patent application Ser. No.13/800,067, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,filed on Mar. 13, 2013, and U.S. Pat. No. 9,345,481, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, for example. U.S. patentapplication Ser. No. 13/803,086, U.S. patent application Ser. No.13/800,067 and U.S. Pat. No. 9,345,481 are each hereby incorporated byreference herein in their respective entireties.

As discussed above, the shaft assembly 1200 can include a proximalportion which is fixably mounted to the handle 1014 and a distal portionwhich is rotatable about a longitudinal axis. The rotatable distal shaftportion can be rotated relative to the proximal portion about the slipring assembly 1600, as discussed above. The distal connector flange ofthe slip ring assembly 1600 can be positioned within the rotatabledistal shaft portion. Moreover, further to the above, the switch drum1500 can also be positioned within the rotatable distal shaft portion.When the rotatable distal shaft portion is rotated, the distal connectorflange and the switch drum 1500 can be rotated synchronously with oneanother. In addition, the switch drum 1500 can be rotated between afirst position and a second position relative to the distal connectorflange. When the switch drum 1500 is in its first position, thearticulation drive system may be operably disengaged from the firingdrive system and, thus, the operation of the firing drive system may notarticulate the end effector 1300 of the shaft assembly 1200. When theswitch drum 1500 is in its second position, the articulation drivesystem may be operably engaged with the firing drive system and, thus,the operation of the firing drive system may articulate the end effector1300 of the shaft assembly 1200. When the switch drum 1500 is movedbetween its first position and its second position, the switch drum 1500is moved relative to distal connector flange. In various instances, theshaft assembly 1200 can comprise at least one sensor configured todetect the position of the switch drum 1500.

Referring again to FIG. 4, the chassis 1240 includes at least one, andpreferably two, tapered attachment portions 1244 formed thereon that areadapted to be received within corresponding dovetail slots 1702 formedwithin a distal attachment flange portion 1700 of the frame 1020. SeeFIG. 3. Each dovetail slot 1702 may be tapered or, stated another way,be somewhat V-shaped to seatingly receive the attachment portions 1244therein. As can be further seen in FIG. 22, a shaft attachment lug 1226is formed on the proximal end of the intermediate firing shaft 1222. Aswill be discussed in further detail below, when the interchangeableshaft assembly 1200 is coupled to the handle 1014, the shaft attachmentlug 1226 is received in a firing shaft attachment cradle 1126 formed inthe distal end 1125 of the longitudinal drive member 1120. See FIG. 3.

Various shaft assembly embodiments employ a latch system 1710 forremovably coupling the shaft assembly 1200 to the housing 1012 and morespecifically to the frame 1020. As can be seen in FIG. 4, for example,in at least one form, the latch system 1710 includes a lock member orlock yoke 1712 that is movably coupled to the chassis 1240. In theillustrated embodiment, for example, the lock yoke 1712 has a U-shapewith two spaced downwardly extending legs 1714. The legs 1714 each havea pivot lug 1715 formed thereon that are adapted to be received incorresponding holes 1245 formed in the chassis 1240. Such arrangementfacilitates pivotal attachment of the lock yoke 1712 to the chassis1240. The lock yoke 1712 may include two proximally protruding lock lugs1716 that are configured for releasable engagement with correspondinglock detents or grooves 1704 in the distal attachment flange 1700 of theframe 1020. See FIG. 3. In various forms, the lock yoke 1712 is biasedin the proximal direction by spring or biasing member (not shown).Actuation of the lock yoke 1712 may be accomplished by a latch button1722 that is slidably mounted on a latch actuator assembly 1720 that ismounted to the chassis 1240. The latch button 1722 may be biased in aproximal direction relative to the lock yoke 1712. As will be discussedin further detail below, the lock yoke 1712 may be moved to an unlockedposition by biasing the latch button the in distal direction which alsocauses the lock yoke 1712 to pivot out of retaining engagement with thedistal attachment flange 1700 of the frame 1020. When the lock yoke 1712is in “retaining engagement” with the distal attachment flange 1700 ofthe frame 1020, the lock lugs 1716 are retainingly seated within thecorresponding lock detents or grooves 1704 in the distal attachmentflange 1700.

When employing an interchangeable shaft assembly that includes an endeffector of the type described herein that is adapted to cut and fastentissue, as well as other types of end effectors, it may be desirable toprevent inadvertent detachment of the interchangeable shaft assemblyfrom the housing during actuation of the end effector. For example, inuse the clinician may actuate the closure trigger 1032 to grasp andmanipulate the target tissue into a desired position. Once the targettissue is positioned within the end effector 1300 in a desiredorientation, the clinician may then fully actuate the closure trigger1032 to close the anvil 1306 and clamp the target tissue in position forcutting and stapling. In that instance, the first drive system 1030 hasbeen fully actuated. After the target tissue has been clamped in the endeffector 1300, it may be desirable to prevent the inadvertent detachmentof the shaft assembly 1200 from the housing 1012. One form of the latchsystem 1710 is configured to prevent such inadvertent detachment.

As can be most particularly seen in FIG. 4, the lock yoke 1712 includesat least one and preferably two lock hooks 1718 that are adapted tocontact corresponding lock lug portions 1256 that are formed on theclosure shuttle 1250. When the closure shuttle 1250 is in an unactuatedposition (i.e., the first drive system 1030 is unactuated and the anvil1306 is open), the lock yoke 1712 may be pivoted in a distal directionto unlock the interchangeable shaft assembly 1200 from the housing 1012.When in that position, the lock hooks 1718 do not contact the lock lugportions 1256 on the closure shuttle 1250. However, when the closureshuttle 1250 is moved to an actuated position (i.e., the first drivesystem 1030 is actuated and the anvil 1306 is in the closed position),the lock yoke 1712 is prevented from being pivoted to an unlockedposition. Stated another way, if the clinician were to attempt to pivotthe lock yoke 1712 to an unlocked position or, for example, the lockyoke 1712 was in advertently bumped or contacted in a manner that mightotherwise cause it to pivot distally, the lock hooks 1718 on the lockyoke 1712 will contact the lock lugs 1256 on the closure shuttle 1250and prevent movement of the lock yoke 1712 to an unlocked position.

Attachment of the interchangeable shaft assembly 1200 to the handle 1014will now be described. To commence the coupling process, the clinicianmay position the chassis 1240 of the interchangeable shaft assembly 1200above or adjacent to the distal attachment flange 1700 of the frame 1020such that the tapered attachment portions 1244 formed on the chassis1240 are aligned with the dovetail slots 1702 in the frame 1020. Theclinician may then move the shaft assembly 1200 along an installationaxis that is perpendicular to the shaft axis SA to seat the attachmentportions 1244 in “operable engagement” with the corresponding dovetailreceiving slots 1702. In doing so, the shaft attachment lug 1226 on theintermediate firing shaft 1222 will also be seated in the cradle 1126 inthe longitudinally movable drive member 1120 and the portions of pin1037 on the second closure link 1038 will be seated in the correspondinghooks 1252 in the closure yoke 1250. As used herein, the term “operableengagement” in the context of two components means that the twocomponents are sufficiently engaged with each other so that uponapplication of an actuation motion thereto, the components may carry outtheir intended action, function and/or procedure.

At least five systems of the interchangeable shaft assembly 1200 can beoperably coupled with at least five corresponding systems of the handle1014. A first system can comprise a frame system which couples and/oraligns the frame or spine of the shaft assembly 1200 with the frame 1020of the handle 1014. Another system can comprise a closure drive system1030 which can operably connect the closure trigger 1032 of the handle1014 and the closure tube 1260 and the anvil 2000 of the shaft assembly1200. As outlined above, the closure tube attachment yoke 1250 of theshaft assembly 1200 can be engaged with the pin 1037 on the secondclosure link 1038. Another system can comprise the firing drive system1080 which can operably connect the firing trigger 1130 of the handle1014 with the intermediate firing shaft 1222 of the shaft assembly 1200.As outlined above, the shaft attachment lug 1226 can be operablyconnected with the cradle 1126 of the longitudinal drive member 1120.Another system can comprise an electrical system which can signal to acontroller in the handle 1014, such as microcontroller, for example,that a shaft assembly, such as shaft assembly 1200, for example, hasbeen operably engaged with the handle 1014 and/or, two, conduct powerand/or communication signals between the shaft assembly 1200 and thehandle 1014. For instance, the shaft assembly 1200 can include anelectrical connector 1810 that is operably mounted to the shaft circuitboard 1610. The electrical connector 1810 is configured for matingengagement with a corresponding electrical connector 1800 on the handlecontrol board 1100. Further details regaining the circuitry and controlsystems may be found in U.S. patent application Ser. No. 13/803,086, andU.S. patent application Ser. No. 14/226,142, the entire disclosures ofeach which were previously incorporated by reference herein. The fifthsystem may consist of the latching system for releasably locking theshaft assembly 1200 to the handle 1014.

Referring now to FIGS. 5-7, the anvil 2000 in the illustrated exampleincludes an anvil body 2002 that terminates in anvil mounting portion2010. The anvil mounting portion 2010 is movably or pivotably supportedon the elongate channel 1310 for selective pivotal travel relativethereto about a fixed anvil pivot axis PA that is transverse to theshaft axis SA. In the illustrated arrangement, a pivot member or anviltrunnion 2012 extends laterally out of each lateral side of the anvilmounting portion 2010 to be received in a corresponding trunnion cradle1316 formed in the upstanding walls 1315 of the proximal end portion1312 of the elongate channel 1310. The anvil trunnions 2012 arepivotally retained in their corresponding trunnion cradle 1316 by thechannel cap or anvil retainer 1290. The channel cap or anvil retainer1290 includes a pair of attachment lugs that are configured to beretainingly received within corresponding lug grooves or notches formedin the upstanding walls 1315 of the proximal end portion 1312 of theelongate channel 1310.

Referring to FIGS. 7, 8 and 9, in at least one arrangement, the distalclosure member or end effector closure tube 3050 employs two axiallyoffset, proximal and distal positive jaw opening features 3060 and 3062.In FIG. 7, the proximal positive jaw opening feature 2060 is located onthe right side (as viewed by a user of the tool assembly) of the shaftaxis SA. The positive jaw opening features 3060, 3062 are configured tointeract with corresponding relieved areas 3064, 3066 and steppedportions formed on the anvil mounting portion 2010 as described infurther detail in U.S. patent application Ser. No. 15/635,631, filedJun. 28, 2017, entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSUREMEMBER, the entire disclosure which has been herein incorporated byreference. Other jaw opening arrangements may be employed.

FIGS. 6 and 7 illustrate one form of an anvil 2000 that includes anelongate anvil body portion 2002 that terminates in an mounting portion2010 that is configured to interact with the end effector closure sleeve3050 to minimize the amount of resultant forces experienced by the endeffector closure tube 3050 as the anvil 2000 is moved from a fully openposition to a closed position and ultimately an over-closed position.The anvil body portion 2002 includes a staple-forming undersurface 2004that has a series of anvil forming pockets (not shown) formed therein.An elongate slot 2006 extends through the body portion 2002 and themounting portion 2010 to facilitate passage of the knife portion or“firing member” 1920 therethrough. In addition, an anvil cover 2030 isattached to the anvil body 2002 to cover the slot 2006. In variouscircumstances, the anvil mounting portion 2010 comprises anvil camsurface 2020 formed thereon. The anvil cam surface 2020 is bisected orotherwise split by the elongate slot 2006. As can be seen in FIGS. 6 and7, a proximal end portion 2032 of the anvil cover 2030 is oriented at anangle that corresponds to the angle/orientation of the anvil camsurfaces 2020. FIGS. 10 and 11 illustrate the anvil 2000 in a fully openposition. As can be seen in FIG. 10, the distal or end effector closuretube 3050 is in its proximal most position when the “second jaw” oranvil 2000 is in its fully open position. When in that position, a camsurface 3072 formed on the distal end 3070 of the end effector closuretube 3050 is not applying any closure forces to the cam closure surfaces2020. As the end effector closure tube 3050 is moved distally, the camsurface 3072 on the end effector closure tube 3050 contacts the camclosure surfaces 2020 on the anvil mounting portion 2010 and acorresponding closure surface 2034 on the proximal end portion 2032 ofthe anvil cover 2030 to pivot the anvil 2000 into a “closed” position.FIGS. 12 and 13 illustrate the positions of the end effector closuretube 3050 and the anvil 2000 when the anvil 2000 is in the closedposition.

As the end effector closure tube 3050 continues to be advanced distallyto apply additional closure motions to the anvil to ultimately move theanvil to an “over-closed” position, the end effector closure tube mayexperience significant stress which may, overtime, cause the endeffector closure tube to become elongated vertically (when viewed froman end) or, stated another way, become somewhat oval in shape which mayultimately lead to failure or otherwise detrimentally effect the abilityto attain a fully closed position. It is axiomatic that when athin-walled tube or cylinder is subjected to internal pressure, a “hoop”and longitudinal stress are produced in the wall of the tube. This hoopstress is acting circumferential and perpendicular to the axis andradius of the cylinder wall. Such hoop stress may be calculated as:

-   -   σ_(h)=pd/(2t), where:    -   σ_(h)=hoop stress (MPa, psi)    -   p=internal pressure in the tube or cylinder (MPa, psi)    -   d=internal diameter of tube or cylinder (mm, in)    -   t=tube or cylinder wall thickness (mm, in)        End effector closure tubes with various tube wall configurations        have been developed. Examples of such tube configurations are        disclosed in U.S. patent application Ser. No. 15/385,903, filed        Dec. 21, 2016, entitled CLOSURE MEMBER ARRANGEMENTS FOR SURGICAL        INSTRUMENTS, the entire disclosure of which is hereby        incorporated by reference herein.

FIGS. 8 and 9 illustrate one form of an end effector closure tube 3050.The closure tube 3050 comprises an external surface 3074 and an internalwall surface 3076. In at least one form, the closure tube 3050 comprisesa constant internal diameter ID and a constant external diameter OD todefine a wall thickness CT that is uniform or constant throughout alength of the closure tube 3050 or at least the portion of the closuretube that is configured to interface with the end effector jaws such asthe anvil 2000 and the elongate channel 1310.

Returning now to FIG. 12, in at least one arrangement, when the anvil2000 is in the “closed position”, a clearance distance “CD” may beobserved between the staple-forming underside 2004 of the anvil body2002 and the cartridge deck surface of a cartridge that is supportedwithin the elongate channel 1310 when no tissue is clamped between theanvil 2000 and the cartridge. FIG. 13 is a cross-sectional view takenalong line 13-13 in FIG. 12 across the closure cam surfaces 2020 as wellas through a distal end portion of the end effector closure tube 3050 aswell as the anvil mounting portion 2020 and the proximal end portion ofthe elongate channel 1310. As can be seen in that Figure, variousclosure forces CF are applied to the anvil 2000 and elongate channel1310 by the end effector closure tube 3050. For example, closure forcesCF are applied onto the closure cam surfaces 2020 and the proximal endportion 2032 of the anvil cap 2030 as well as onto the elongate channel1310.

In the example illustrated in FIGS. 6-15, the anvil mounting portion2020 is formed to establish a plurality of discrete load transferlocations that are configured to be contacted by the inner surface 3076of the end effector closure tube 3050 when the end effector closure tube3050 is in the position corresponding to the closed position of theanvil 2000. In at least one arrangement, at least two discrete loadtransfer locations are located on each side of a vertical plane VP thatbisects the anvil 2000 when the anvil 2000 is in the closed position.For example, in FIG. 13, a first right load transfer location or edge2070R, a second right load transfer location or edge 2072R, a thirdright load transfer location or edge 2074R and a fourth right loadtransfer location or edge 2076R are formed on a right side of thevertical plane VP. Similarly, a first left load transfer location oredge 2070L, a second left load transfer location or edge 2072L, a thirdleft load transfer location or edge 2074L and a fourth left loadtransfer location or edge 2076L are formed on a left side of thevertical plane VP. As used in this context, the term “at least twodiscrete load transfer locations” means that the load transfer locationsare formed relative to each other so that a space or clearance is formedbetween the portion of the anvil mounting portion 2010 extending betweenthe load transfer locations and the inner surface 3076 of the endeffector closure tube 3050.

For example, a first amount of clearance CR₁ is formed between the innersurface 3076 of the end effector closure tube 3050 extending between thefirst right load transfer location 2070R and the second right loadtransfer location 2072R. A second amount of clearance CR₂ is formedbetween the inner surface of the end effector closure tube 3050extending between the third right load transfer location 2072R and thethird right load transfer location 2074R. A third amount of clearanceCR₃ is formed between the third right load transfer location 2074R andthe fourth right load transfer location 2076R. A first amount ofclearance CL₁ is formed between the inner surface of the end effectorclosure tube extending between the first left load transfer location2070L and the second left load transfer location 2072L. A second amountof clearance CL₂ is formed between the inner surface 3076 of the endeffector closure tube extending between the second left load transferlocation 2072L and the third left load transfer location 2074L. A thirdamount of clearance CL₃ is formed between the third left load transferlocation 2074L and the fourth left load transfer location 2076L. In atleast one arrangement, the closure forces CF applied to the closure camsurfaces 2020, as well as the proximal portion 2032 of the anvil cap2030 may be evenly distributed between the first right load transferlocation 2070R and the first left load transfer location 2070L.Likewise, the closure forces CF applied to the elongate channel 1310 maybe evenly distributed between the fourth right load transfer location2076R and the fourth left load transfer location 2076L, for example.

In at least one arrangement, at least two right load transfer locations2070R, 2072R and at least two left load transfer locations 2070L, 2072Lare located on one side of a horizontal plane HP that bisects the endeffector 1300. As illustrated in FIG. 13, the two right load transferlocations 2070R, 2072R are located on an opposite side of vertical planeVP from the two left load transfer locations 2070L, 2072L. Also in atleast one arrangement, the third right load transfer location 2074R andthe fourth right load transfer location 2076R are located on an oppositeside of the horizontal plane HP from the first right load transferlocation 2070R and the second right load transfer location 2072R.Similarly, third left load transfer location 2074L and the fourth leftload transfer location 2076L are located on a opposite side of thehorizontal plane HP from the first left load transfer location 2070L andthe second left load transfer location 2072L. The right load transferlocations 2074R, 2076R are located on an opposite side of vertical planeVP from the two left load transfer locations 2074L, 2076L. As can beseen in FIGS. 6 and 10, the load transfer locations may be formed byscalloped or relieved areas 2080, 2082, 2084 so that the load transferlocations comprise corners formed from adjoining surfaces. Other loadtransfer location shapes are contemplated.

FIGS. 14 and 15 illustrate the anvil 2000 and the end effector closuretube 3050 in an “over-closed” state that is created as the end effectorclosure tube 3050 is advanced further distally after the anvil 2000 hasattained the closed position. In at least one example, the anvil 2000 isin an “over-closed state” when a distal end portion 2003 of the bodyportion 2002 of the anvil 2000 is in contact with the cartridge deck ofthe staple cartridge that is operably supported with the elongatechannel 1310. See FIG. 14. Continued distal advancement of the endeffector closure tube 3050 after the anvil 2000 has attained the closedposition may significantly increase the hoop stress formed in the endeffector closure tube 3050 which may cause the end effector closure tubeto effectually fail or vertically elongate which can detrimentallyeffect the proper closure of the anvil when used in future applications.As be seen in FIG. 15, the first right amount of clearance CR₁ and thefirst left amount of clearance CL₁ may each have a clearance width CW₁that is located on a common side of the horizontal plane HP. The secondright amount of clearance CR₂, and the second left amount of clearanceCL₂ each span across the horizontal plane HP. Stated another way,portions of the second right amount of clearance CR₂ are located on eachside of the horizontal plane HP and portions of the second left amountof clearance CL₂ are located on each side of the horizontal plane HP.

Forming at least two discrete load transfer locations located on eachside of the vertical plane may reduce the amount of detrimental hoopstresses established in the end effector closure tube 3050 as it isdistally moved into the over-closed position. By forming at least threeload transfer locations located on each side of the vertical plane mayfurther reduce the amount of detrimental hoop stresses established inthe end effector closure tube 3050 as it is distally moved into theover-closed position. Forming at least four load transfer locationslocated on each side of the vertical plane may further reduce the amountof detrimental hoop stresses established in the end effector closuretube 3050 as it is distally moved into the over-closed position. Sucharrangements therefor enable the end effector closure tube 3050 to bemade with a constant wall thickness as described above, which may reducethe amount of manufacturing costs associated with manufacturing the endeffector closure tube.

FIGS. 16-22 illustrate an alternative anvil 2000′ that is substantiallyidentical to anvil 2000 described above expect for the differencesdiscussed below. As can be seen in FIG. 16, the anvil mounting portion2010′ is formed with continuous arcuate anvil camming surfaces 2020′that are not interrupted by any load transfer locations. FIGS. 17 and 18illustrate the anvil 2000′ in a fully open position. As can be seen inFIG. 17, the end effector closure tube 3050′ is in its proximal mostposition when the “second jaw” or anvil 2000′ is in its fully openposition. When in that position, the end effector closure tube 3050′ isnot applying any closure forces to the cam closure surfaces 2020′.

FIG. 23 illustrates one form of an end effector closure tube 3050′ thatmay be identical to the end effector closure tube 3050 described above,except for the differences noted below. The end effector closure tube3050′ comprises an external surface 3074′ and an internal wall surface3076′. In at least one form, the closure tube 3050′ has a constant wallthickness WT₁ except for a segment A_(s) of the wall located at the topof the end effector closure tube 3050′that has a thicker wall thicknessWT₂ that is greater than WT₁. Such arrangement forms a single loadtransfer location 2070′.

FIGS. 19 and 20 illustrate the positions of the end effector closuretube 3050′ and the anvil 2000′ when the anvil 2000′ is in the closedposition. As can be seen in FIG. 20, as the end effector closure tube3050′ is moved distally, the load transfer location 2070′ on the endeffector closure tube 3050′ contacts the cam surface 2034 on theproximal portion 2032 of the anvil cap 2030. The end effector closuretube 3050′ also contacts portions of the elongate channel 1310 on eachside of the vertical plane VP that bisects the end effector. The loadtransfer location 2070′ may span across the entire cam surface 2034 tocontact an upper portion of the cam surfaces 2020′ on each side of thevertical plane VP as shown in FIG. 20. When in the closed position shownin FIGS. 19 and 20, such arrangement serves to form a space 3077 betweenthe corresponding portions of the inner surface 3076′ of the endeffector closure tube 3050′ and the cam surfaces 2020′ of the anvilmounting portion 2010′ as shown in FIG. 20. The spaces 3077 each extendfrom the load transfer location 2070′ and the area wherein the innersurface 3076′ contacts the elongate channel 1310 (space distance S_(D)).Thus, when the anvil 2000′ is moved to a closed position, there is adiscrete first load transfer location 2070′ located on one side of ahorizontal plane HP and two discrete load transfer locations 2072R′,2072L′ locations located on an opposite side of the horizontal plane HP.The discrete first load transfer location 2070′ is separated from eachof the discrete load transfer locations 2072R′, 2072L′ by spaces 3077when the anvil 2000′ is in the closed position. See FIG. 20. As can alsobe seen in FIG. 20, the load transfer locations 2072R′, 2072L′ arelocated on opposite sides of the vertical plane VP.

FIGS. 21 and 22 illustrate the interrelationship between the endeffector closure tube 3050′ and the anvil 2000′ when the end effectorclosure tube 3050′ has moved the anvil 2000′ in an over-closedorientation. As can be seen in FIG. 22, when in the over-closedposition, the end effector closure tube 3050′ contacts the anvil 2000′and the elongate channel 1310 to form a discrete load transfer location2070′ that is separated from discrete load transfer locations 2074R′,2074L′ by spaces 3079R, 3079L. The discrete load transfer location2074R′ is separated by the discrete load transfer location 2076R′ by aspace 3081R and the discrete load transfer location 2074L′ is separatedfrom a discrete load transfer location 2076L′ by a space 3081L. Thus, inthis arrangement, at least one discrete load transfer location (2070′)spans a vertical plane VP that bisects the end effector and at least twodiscrete load transfer locations span a horizontal plane HP that bisectsthe end effector. In addition, at least one discrete load transferlocation is located on each side of the horizontal plane HP and at leastone discrete load transfer location is located on each side of thevertical plane VP. Such arrangement of load transfer locations in theabove manner may help to prevent the vertical elongation of the endeffector closure tube 3050′.

FIGS. 24-30 illustrate an alternative anvil 2000″ that is substantiallyidentical to anvil 2000 described above expect for the differencesdiscussed below. As can be seen in FIG. 24, the anvil mounting portion2010″ is formed with an arcuate anvil camming surface 2020″ and rightand left notched or recessed portions 2022″. FIGS. 24 and 25 illustratethe anvil 2000″ in a fully open position. As can be seen in FIG. 24, theend effector closure tube 3050″ is in its proximal most position whenthe “second jaw” or anvil 2000″ is in its fully open position. When inthat position, the end effector closure tube 3050″ is not applying anyclosure forces to the cam closure surfaces 2020″. FIG. 30 illustratesone form of an end effector closure tube 3050″ that may be identical tothe end effector closure tube 3050 described above, except for thedifferences noted below. The end effector closure tube 3050″ comprisesan external surface 3074″ and an internal wall surface 3076″. In atleast one form, the closure tube 3050″ has a first wall thickness WT₁, asecond wall thickness WT₂, a third wall thickness WT₃, and a fourth wallthickness WT₄ that are arranged as shown in FIG. 30. In at least onearrangement, for example, WT₁<WT₂<WT₃≤WT₄. In some cases, WT₃>WT_(4.)The portion of the end effector closure tube 3050″ that has a wallthickness corresponding to WT₄ forms a load transfer location 2070″. Inthe illustrated arrangement, for example, the load transfer location2070″ spans across a vertical plane VP that bisects the end effectorclosure tube 3050″. The portions of the end effector closure tube 3050″that have a wall thickness WT₃ form load transfer locations 2072R″,2072L″. In at least one arrangement as shown in FIG. 30, the loadtransfer locations 2072R″, 2072L″ span across a horizontal plane HP thatbisects the end effector closure tube 3050″.

Referring now to FIGS. 26 and 27, as the end effector closure tube 3050″is moved distally, the load transfer location 2070″ contacts the camsurface 2034 on the proximal portion 2032 of the anvil cap 2030. Theload transfer locations 2072R″, 2072L″ also contact correspondingportions of the anvil mounting portion 2010″. Also portions of the endeffector closure tube 3050″ form load transfer locations 2074R″, 2074L″that contact corresponding portions of the elongate channel 1310 to movethe anvil 2000″ to the closed position shown in FIGS. 26 and 27. When inthe closed position shown in FIGS. 26 and 27, such arrangement serves toform a space 3077″, 3079″ between the corresponding portions of theinner surface 3076″ of the end effector closure tube 3050″ and the camsurfaces 2020″ of the anvil mounting portion 2010″ as shown in FIG. 27.The spaces 3077″ are located between the load transfer location 2070″and the load transfer locations 2072R″, 2072L″. The spaces 3079″ arelocated between the load transfer locations 2072R″, 2072L″ and the loadtransfer locations 2074R, 2074L″ as shown in FIG. 27.

FIGS. 28 and 29 illustrate the interrelationship between the endeffector closure tube 3050″ and the anvil 2000″ when the end effectorclosure tube 3050″ has moved the anvil 2000″ into an over-closedorientation. As can be seen in FIG. 29, in addition to the load transferlocations 2070″, 2072R″, 2072L″, 2074R″, 2074L″, discrete load transferlocations 2076R″, 2076L″ are formed by the edge of the recessed portions2022″formed on the anvil mounting portion 2010″. Such discrete loadtransfer locations 2076R″, 2076L″ are separated from the correspondingdiscrete load transfer locations 2072R″. 2072L″ by corresponding spaces3081″. The provision of the discrete load transfer locations in theabove manner may help to prevent the vertical elongation of the endeffector closure tube 3050″.

When using an end effector 1300 of the type and construction describedherein, a clinician manipulates the first and second jaws (the anvil2000 and the elongate channel 1310 that has a surgical staple cartridgeoperably mounted therein), to capture the tissue to be cut and stapled(the “target tissue”) therebetween. As can be seen in FIGS. 5 and 7, forexample, a surgical staple cartridge 4000 comprises a cartridge body4010 that is configured to be removably supported within the elongatechannel 1310. The cartridge body 4010 includes an elongate cartridgeslot 4016 that extends from a proximal end 4012 through the cartridgebody 4010 to a distal end portion 4014 to enable the knife member orfiring member 1920 to pass therethrough. The cartridge body 4010 furtherdefines a cartridge deck surface 4020 on each side of the elongate slot4016. A plurality of staple cavities 4022 are provided in the cartridgebody 4010 on each side of the elongate slot 4016. Each cavity 4022 opensthrough the deck surface 4020 to removably support a surgical staple orstaples therein. In at least one cartridge arrangement, three lines ofstaple cavities 4022 are provided on each side of the elongate slot4016. The lines are formed such that the staples in a center line arestaggered relative to the staples in the two adjacent outer lines. Thestaples are supported on staple drivers that are movably supportedwithin each staple cavity. In at least some arrangements, the stapledrivers are arranged to be contacted or “fired” upward when contacted bya cam member or camming portions associated with the knife member 1920,for example. In some arrangements, a wedge sled or camming sled ismovably supported in the cartridge body and is adapted to be axiallydisplaced through the cartridge body as the knife member 1920 is axiallydeployed through the cartridge from the proximal end portion 4012 to thedistal end portion 4014 of the cartridge body 4010. The wedge sledincludes a camming member or wedge associated with each line of staplecavities so as to serially deploy the staple drivers supported therein.As the cam contacts a staple driver, the driver is driven upwardlywithin the staple cavity driving the staple or staples supported thereonout of the staple cavity through the clamped tissue and into formingcontact with the staple-forming undersurface of the anvil. The wedgesled or camming member is located distal to the knife or tissue cuttingedge of the knife or firing member 1920, so that the tissue is stapledprior to be severed by the tissue cutting edge.

When the clinician initially locates the target tissue between the anviland the staple cartridge, it is important that the target tissue belocated so that the knife does not cut into the target tissue unless itis first stapled. In previous anvil arrangements, tissue stops areprovided on the proximal end of the anvil body to prevent the targettissue from moving proximally past the proximal most staple pockets inthe staple cartridge. Such tissue stops form abrupt proximal ends thatconfront or face the distal end of the end effector closure tube. As theclosure tube is moved distally to close the anvil, tissue extendingoutward from between the anvil and the cartridge occasionally willbecome undesirably pinned or pinched between the proximal ends of thetissue stops and the distal end of the end effector closure tube. Theexamples disclosed below are configured to minimize the possibility oftissue being pinched between the tissue stops and the end effectorclosure tube when the anvil is being moved to the closed and over-closedpositions in the various manners described herein.

Turning to FIG. 7, for example, the staple cartridge 4000 includesstaples (not shown) that are removably supported or stored in each ofthe proximal most staple cavities 4022P located in the lines of staplecavities 4022 located in the cartridge body 4010 on each side of theelongate slot 4016. In various circumstances, to prevent the targettissue from being clamped proximal to the staples in the proximal moststaple cavities 4022P, the anvil 2000 includes two tissue stop members2040 that protrude downwardly past the staple-forming undersurface oneach side of the anvil body. When the anvil is in a closed position orin an over-closed position, each of the tissue stop members 2040protrude downwardly on each side of the cartridge body 4010. FIG. 7illustrates the anvil 2000 in an open configuration. As can be seen inthat Figure, each of the tissue stops 2040 extend below the cartridgedeck surface to prevent the target tissue from extending proximally pastthe staples in the proximal most staple cavities 4022P. As can be seenin FIGS. 7, 31 and 32, in at least one arrangement, the tissue stops2040 are integrally formed with the anvil body portion 2002. The anvilbody portion 2002 and the proximal ends of the tissue stops 2040 extendslightly above the corresponding camming surfaces 2020 formed on theanvil mounting portion 2010. In the illustrated example, the proximalends of the tissue stops 2040 are segmented into an upper proximal endportion 2042, a lower proximal end portion 2043 and a bottom proximalend portion 2044. See FIGS. 31 and 32. As can also be seen in FIGS. 31and 32, an angled surface or chamfer surface 2045 is formed between theupper proximal end portion 2042 and the camming surface 2020 on theanvil mounting portion. An angled surface or chamfer surface 2046 isformed between the lower proximal end portion 2043 and the cammingsurface 2020 and an angled surface or chamfer surface 2047 is formedbetween the bottom proximal end portion 2044 and the camming surface2020. In the illustrated arrangement wherein scalloped or relieved areas2080, 2082, 2084 are formed in the anvil mounting portion 2010, thechamfer 2045 corresponds to the relieved area 2080. See FIG. 33. Thelower proximal end portion 2043 and accompanying chamfer 2046 correspondto relieved area 2082 and the bottom proximal end portion 2044 andaccompanying chamfer 2047 corresponds to relieved area 2084.

As discussed above, the anvil 2000 is moved from a fully open positionto the closed position and an over-closed position by the axiallymovable end effector closure tube 3050. FIGS. 31 and 33 illustrate theposition of the end effector closure tube 3050 relative to the tissuestops 2040 when the anvil 2000 is in the closed position. As can be seenin FIG. 33, the upper proximal end portion 2042 and accompanying chamfer2045 are approximately parallel to a corresponding portion of a distalend 3051 of the end effector closure tube 3050. To reduce a possibilityof tissue being inadvertently pinched between the tissue stops 2040 andthe distal end 3051 of the end effector closure tube 3050, the lowerproximal end portion 2043 and the bottom proximal end portion 2044 ofthe tissue stop 2040 and the corresponding chamfers 2046 and 2047 angleaway from the distal end 3051 of the end effector closure tube 3050.This arrangement has the practical effect of increasing a distancebetween the portion of the tissue stop and the end effector closure tubethat may most likely encounter adjacent tissue.

FIG. 33 is an enlarged view of a portion of the end effector depicted inFIG. 31 wherein the anvil 2000 is in a closed position. When in thatposition, the upper proximal end portion 2042 of each tissue stops 2040is located a first tissue distance TD₁ from the distal end 3051 of theend effector closure tube 3050. The bottom proximal end portion 2044 ofeach tissue stop 2040 is located a second tissue distance TD₂ from thedistal end 3051 of the end effector closure tube 3050. As can be seen inthat Figure, TD₂>TD₁. FIGS. 32 and 34 depict the anvil 2000 in anover-closed position. The first tissue distance TD₁′ between the upperproximal end portion 2042 of each tissue stop 2040 is still slightlyless than the second tissue distance TD₂′ between the bottom proximalend portion 2044 of each tissue stop 2040 and the distal end 3051 of theend effector closure tube 3050 which will still reduce the likelihood oftissue pinch therebetween. In at least one example, TD₂ and/or TD₂′ maybe approximately ten thousands of an inch to approximately twenty-fivethousands of an inch. However, other gaps may be attained. Also, theinclusion of the chamfered surfaces 2045, 2046 and 2047 may help tolessen the likelihood of pinching tissue between the tissue stops 2040and the distal end 3051 of the end effector closure tube 3050 when theanvil 200 is moved to the closed and over-closed positions. The personof ordinary skill in the art will appreciate that the above-describedtissue stop configurations will also work with other forms of endeffector closure tube and closure member arrangements.

FIGS. 35-38 illustrate another anvil embodiment 5000 that is identicalto anvil 2000 described above except for the differences relating totissue stops 5040. Tissue stops 5040 may be identical to tissue stops2040 except that proximal end portions 5042, 5043, 5044 of each tissuestop and the accompanying chamfer surfaces 5045, 5046, 5047 areapproximately parallel to the distal end 5031 of the end effectorclosure tube 5030. End effector closure tube 5050 may otherwise beidentical to end effector closure tube 3050 described above, except forthe differences discussed below. FIGS. 35 and 36 illustrate the anvil5000 in the closed position. In this arrangement, an area that mayotherwise be susceptible to pinching tissue is the edge of the bottomproximal end portion 5044 and the confronting portion of the distal end5031 of the end effector closure tube 5050. To alleviate and minimizesuch possibility, a relieved area 5060 is formed in the distal end 5031of the end effector closure tube 5030 that confronts or, stated anotherway, is opposite from the bottom proximal end 5044 of each of the tissuestops 5040. In the illustrated example, each relieved area 5060comprises an arcuate notch 5062 that is formed in the portion of thedistal end 5031 of the end effector closure tube 5030 corresponding tothe bottom proximal end portion 5044 of each tissue stop 5040. In theillustrated arrangements, for example, the bottom proximal end portion5044 of each of the tissue stops 5040 terminates in a bottom corner 5070and the apex or bottom 5064 is directly across from the bottom corner5070 when the end effector closure tube 5050 is in the positioncorresponding to the closed position of the anvil 5000. Other notchshapes, however, may be employed.

FIG. 36 is an enlarged view of a portion of the end effector depicted inFIG. 35 wherein the anvil 5000 is in a closed position. When in thatposition, the upper proximal end portion 5042, the lower proximal endportion 5043 and the bottom proximal end portion 5044 of each tissuestop 5040 are located a first tissue distance TD₁ from the distal end3051 of the end effector closure tube 5050. The bottom proximal endportion 5044 of each tissue stop 5040 is located a second tissuedistance TD₂ from the apex or bottom 5064 of the notch 5062 in thedistal end 5051 of the end effector closure tube 5050. As can be seen inthat Figure, TD₂>TD₁. FIGS. 37 and 38 depict the anvil 5000 in anover-closed position. The first tissue distance TD₁′ between the bottomproximal end portion 5044 of each tissue stop 5040 is still less thanthe second tissue distance TD₂′ between the bottom proximal end portion5044 of each tissue stop 2040 and the apex 5064 of the correspondingnotch 5062 in the distal end 5051 of the end effector closure tube 5050which will still reduce the likelihood of tissue pinch therebetween.Also, the inclusion of the chamfered surfaces 5045, 5046 and 5047 mayhelp to lessen the likelihood of pinching tissue between the tissuestops 5040 and the distal end 5051 of the end effector closure tube 5050when the anvil 5000 is moved to the closed and over-closed positions.The person of ordinary skill in the art will appreciate that theabove-described tissue stop configurations will also work with otherforms of end effector closure tube and closure member arrangements.

FIG. 39 illustrates a previous surgical staple cartridge 4000 thatincludes a cartridge body 4010 that is configured to be removablysupported within the elongate channel 1310. The cartridge body 4010includes an elongate cartridge slot 4016 that extends from a proximalend 4012 through the cartridge body 4010 to a distal end portion 4014 toenable the knife member or firing member 1920 (FIG. 5) to passtherethrough. The cartridge body 4010 further defines a cartridge decksurface 4020 on each side of the elongate slot 4016. See FIG. 39. Aplurality of staple cavities 4022 are provided in the cartridge body4010 on each side of the elongate slot 4016. Each cavity 4022 opensthrough the deck surface 4020 to removably support a surgical staple orstaples therein. In at least one cartridge arrangement, three lines ofstaple cavities 4022 are provided on each side of the elongate slot4016. In the illustrated example, the lines are formed such that thestaples in a center line are staggered relative to the staples in thetwo adjacent outer lines. The staples are supported on staple driversthat are movably supported within each staple cavity. In at least somearrangements, the staple drivers are arranged to be contacted or “fired”upward when contacted by a cam member or camming portions associatedwith the knife member 1920, for example. In some arrangements, a “wedge”sled or camming sled is movably supported in the cartridge body 4010 andis adapted to be axially displaced through the cartridge body 4010 asthe knife member 1920 is axially deployed through the cartridge from theproximal end portion 4012 to the distal end portion 4014 of thecartridge body 4010. The wedge sled includes a camming member or “wedge”associated with each line of staple cavities so as to serially deploythe staple drivers supported therein. As the corresponding wedge or camcontacts a staple driver, the driver is driven upwardly within thestaple cavity thereby driving the staple or staples supported thereonout of the staple cavity through the clamped tissue and into formingcontact with the staple-forming undersurface of a confronting anvil ofthe end effector. The wedge sled or camming member is located distal tothe knife or tissue cutting edge of the knife or firing member 1920, sothat the tissue is stapled prior to being severed by the tissue cuttingedge on the knife or firing member.

Variations to the arrangement and/or geometry of staples in a stapleline can affect the flexibility and sealing properties of the stapleline. For example, a staple line comprised of linear aligned staples canprovide a limited amount of flexibility or stretch because the stapleline can flex or stretch between the linear staples. Consequently, alimited portion of the staple line (e.g., the portion between staples)is flexible. A staple line comprised of angularly-oriented staples canalso flex or stretch between the staples. However, theangularly-oriented staples are also able to rotate, which provides anadditional degree of stretch within the staple line. A staple linecomprised of angularly-oriented staples may be capable of stretching inexcess of 60%, for example. In certain instances, a staple linecomprised of angularly-oriented staples can stretch at least 25% or atleast 50%, for example. The arrangement of staples includes the relativeorientation of the staples and the spacing between the staples, forexample. The geometry of the staples includes the size and shape of thestaples, for example. The flexibility and sealing properties of a stapleline can change at longitudinal and/or lateral positions based on thearrangement and/or geometry of the staples. In certain instances, it isdesirable to alter the flexibility and/or sealing properties of a stapleline at one or more locations along the staple line. For example, it canbe desirable to maximize the flexibility of the staple line or a portionthereof. Additionally or alternatively, it can be desirable to minimizethe flexibility of the staple line or a portion thereof. It can also bedesirable to maximize the sealing properties of the staple line or aportion thereof. Additionally or alternatively, it can be desirable tominimize the sealing properties of the staple line or a portion thereof.

The arrangement of staple cavities in a staple cartridge corresponds tothe arrangement of staples in a staple line generated by the staplecartridge. For example, the spacing and relative orientation of staplecavities in a staple cartridge corresponds to the spacing and relativeorientation of staples in a staple line generated by the staplecartridge. In various instances, a staple cartridge can include anarrangement of staples cavities that is selected and/or designed tooptimize the flexibility and/or sealing properties of the resultantstaple line. A surgeon may select a staple cartridge having a particulararrangement of staple cavities based on the surgical procedure to beperformed and/or the properties of the tissue to be treated during thesurgical procedure, for example.

In certain instances, it can be desirable to generate a staple line withdifferent staple patterns. A staple line can include a first pattern ofstaples for a first portion thereof and a second pattern of staples fora second portion thereof. The first pattern and the second pattern canbe longitudinally offset. For example, the first pattern can bepositioned at the proximal or distal end of the staple line. In otherinstances, the first pattern and the second pattern can be laterallyoffset and, in still other instances, the first pattern and the secondpattern can be laterally offset and longitudinally offset. A staple linecan include at least two different patterns of staples.

In certain instances, the majority of staples in a staple line can forma major pattern and other staples in the staple line can form one ormore minor patterns. The major pattern can span a significant portion ofthe staple line and can include a longitudinally-repetitive sub-pattern.In certain instances, the minor pattern, or irregularity, can deviatefrom the major pattern. The minor pattern can be an anomaly at one ormore locations along the length of the staple line, for example. Thedifferent patterns in a staple line can be configured to producedifferent properties at predefined locations. For example, the majorpattern can be a highly flexible or elastic pattern, which can permitextensive stretching of the stapled tissue, and the minor pattern can beless flexible or less elastic. It can be desirable for the majority ofthe staple line to be highly flexible and for one or more limitedportions to be less flexible, for example. In other instances, the minorpattern can be more flexible than the major pattern. In certaininstances, because the minor pattern extends along a shorter portion ofthe staple line, the flexibility of the minor pattern may not impact, ormay not significantly impact, the overall flexibility of the entirestaple line. U.S. patent application Ser. No. 15/385,389, entitledSTAPLE CARTRIDGE AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIESTHEREIN, now U.S. Patent Application Publication No. 2018/0168629, theentire disclosure of which is hereby incorporated by reference hereindiscloses various staple cartridge and staple driver arrangements. U.S.Pat. No. 9,801,627, entitled FASTENER CARTRIDGE FOR CREATING FLEXIBLESTAPLE LINES, the entire disclosure of which is hereby incorporated byreference herein discloses various cartridge an anvil arrangements forcreating flexible lines of surgical staples.

Referring again to FIG. 39, the majority of the staple cavities 4022 inthe cartridge 4000 are arranged in a first pattern, or major pattern,4030. The first pattern 4030 is a longitudinally-repetitive pattern ofangularly-oriented staple cavities 4022. Longitudinally-repetitivepatterns are patterns in which a sub-pattern or arrangement islongitudinally repeated. For example, an arrangement of three staplecavities on each side of the slot 4016 (an inner staple cavity, anintermediate staple cavity, and an outer staple cavity) can be repeatedalong at least a portion of the length of the staple cartridge body4010. Various longitudinally-repetitive patterns of angularly-orientedstaples cavities are described in U.S. patent application Ser. No.14/498,145, filed Sep. 26, 2014, now U.S. Patent Application PublicationNo. 2016/0089142, entitled METHOD FOR CREATING A FLEXIBLE STAPLE LINE,which is hereby incorporated by reference herein in its entirety. Theopenings 4024 of the staple cavities 4022 in the first pattern 4030 forma herringbone pattern having six rows of angularly-oriented staplecavity openings 4024 in the cartridge deck surface 4020. An inner row4026 a, an intermediate row 4026 b, and an outer row 4026 c of staplecavities 4022 are positioned on each side of the slot 4016.

Each staple cavity opening 4024 has a proximal end 4027 and a distal end4028. The proximal end 4027 and the distal end 4028 of the staplecavities 4022 in the first pattern 4030 are laterally offset. Stateddifferently, each staple cavity 4022 in the first pattern 4030 isangularly oriented relative to a longitudinal staple cartridge axis SCA.A cavity axis CA extends between the proximal end 4027 and the distalend 4028 of each opening 4024. The cavity axes CA are obliquely orientedrelative to the slot 4016. More specifically, the openings 4024 in theinner rows 4026 a of staple cavities 4022 and the outer rows 4026 c ofstaple cavities 4022 are oriented at 45 degrees, or about 45 degrees,relative to the longitudinal staple cartridge axis SCA, and the openings4024 in the intermediate rows 4026 b of staple cavities 4022 areoriented at 90 degrees, or about 90 degrees, relative to the openings4024 of the inner rows 4026 a and the outer rows 4026 c.

In the example of FIG. 39, certain staple cavities in the cartridge body4010 are oriented at an angle that is anomalous or irregular withrespect to the staple cavities 4022 in the first pattern 4030. Morespecifically, the angular orientation of proximal staple cavities 4022a, 4022 b, 4022 c, and 4022 d and distal staples cavities 4022 e, 4022f, 4022 g, and 4022 h does not conform to the herringbone arrangement ofthe staple cavities 4022 in the first pattern 4030. Rather, the proximalstaple cavities 4022 a-4022 d and the distal staple cavities 4022 e-4022h are angularly offset from the staple cavities 4022 in the firstpattern 4030. The proximal staple cavities 4022 a, 4022 b, 4022 c, and4022 d are obliquely oriented relative to the staples cavities 4022 inthe first pattern 4030, and the distal staple cavities 4022 e, 4022 f,4022 g, and 4022 h are also obliquely oriented relative to the staplescavities 4022 in the first pattern 4030. The proximal and distal staplecavities 4022 a-4022 h are oriented parallel to the slot 4016 and to thelongitudinal staple cartridge axis SCA.

The proximal staple cavities 4022 a-4022 d form a proximal pattern 4040that is distinct from the first pattern 4030, and the distal staplecavities 4022 e-4022 h form a distal pattern 4042 that is also distinctfrom the first pattern 4030. In the depicted arrangement, the proximalpattern 4040 includes a first pair of parallel, longitudinally-alignedstaple cavities 4022 a, 4022 b on a first side of the slot 4016 and asecond pair of parallel, longitudinally-aligned staple cavities 4022 c,4022 d on a second side of the longitudinal slot 4016. The distalpattern 4042 also includes a first pair of parallel,longitudinally-aligned staple cavities 4022 e, 4022 f on the first sideof the longitudinal slot 4016 and a second pair of parallel,longitudinally-aligned staple cavities 4022 g, 4022 h on the second sideof the longitudinal slot 4016. In other instances, the distal pattern4042 can be different from the proximal pattern 4040.

The proximal pattern 4040 and the distal pattern 4042 are symmetricrelative to the longitudinal staple cartridge axis SCA. In otherinstances, the proximal pattern 4040 and/or the distal pattern 4042 canbe asymmetric relative to the longitudinal staple cartridge axis SCA.For example, the staple cavities 4022 e and 4022 f can be longitudinallyoffset from the staple cavities 4022 g and 4022 h and/or the staplecavities 4022 a and 4022 b can be longitudinally offset from the staplecavities 4022 c and 4022 d. Additionally or alternatively, in certaininstances, the staple cartridge body 4010 can include either theproximal pattern 4040 or the distal pattern 4042. In other instances,the staple cavities 4022 defined in the staple cartridge body 4010 caninclude additional and/or different patterns of staple cavities 4022.

As can be further seen in FIG. 39, atraumatic extenders 4050 extend orprotrude from the deck surface 4020 around a portion of the staplecavities 4022 in the first pattern 4030. The atraumatic extenders 4050surround the proximal and distal ends 4027 and 4028, respectively, ofthe openings 4024 of the staple cavities 4022 in the first pattern 4030.The atraumatic extenders 4050 may be configured to grip tissue that isclamped by the end effector. Additionally or alternatively, in certaininstances, the tips of the staple legs can protrude from the cartridgebody 4010. In such instances, the atraumatic extenders 4050 may beconfigured to extend flush with and/or beyond the tips of the staplelegs to prevent the tips from prematurely penetrating tissue.Consequently, larger staples, e.g., staples having longer legs, can bepositioned in the staple cavities 4022 having atraumatic extenders 4050positioned therearound. For example, referring again to FIG. 39, largerstaples can be positioned in the staple cavities 4022 in the firstpattern 4030 than the staples in the staple cavities in the proximalpattern 4040 and the distal pattern 4042 without risking prematurepiercing of tissue by the longer staple legs. In certain instances,atraumatic extenders 4050 can be positioned around staples cavities 4022in the proximal pattern 4040 and/or the distal pattern 4042, and largerstaples can be positioned in one of more of those staple cavities 4022a-4022 h, as well.

The staple cartridge body 4010 can be configured to generate a stapleline having different properties along the length thereof. A staple line4060 generated by the staple cartridge body 4010 and embedded in tissueT is depicted in FIG. 40. The staple line 4060 is comprised of staples4062, and an exemplary staple 4062 for use with various staplecartridges described herein is depicted in FIG. 41. The staple 4062 canbe comprised of a bent wire, for example. The wire can have a diameterof 0.0079 inches, or approximately 0.0079 inches. In other instances,the wire can have a diameter of 0.0089 inches, or approximately 0.0089inches. In still other instances, the wire can have a diameter of0.0094, or approximately 0.0094 inches. In certain instances, the wirecan have a diameter of less than 0.0079 inches or more than 0.0094inches. The reader will appreciate that the diameter of the wire candictate the diameter of the staple. The staple 4062 is a substantiallyU-shaped staple having a base 4064, a first leg 4066 extending from afirst end of the base 4064, and a second leg 4068 extending from asecond end of the base 4064. The first leg 4066 is substantiallyparallel to the second leg 4068 and substantially perpendicular to thebase 4064. When implanted in tissue T, the angular orientation of thebase 4064 corresponds to the angular orientation of the staple cavityopening 4024 from which the staple 4062 was fired.

Another exemplary staple 4070 that may be used with various staplecartridges described herein is depicted in FIG. 42. The staple 4070 is asubstantially “V-shaped” staple having a base 4072, a first leg 4074extending from a first end of the base 4072, and a second leg 4076extending from a second end of the base 4072. The first leg 4074 isobliquely oriented relative to the second leg 4076 and the base 4072.When implanted in tissue T, the orientation of the base 4072 correspondsto the orientation of the staple cavity opening 4024 from which thestaple 4070 was fired. The reader will appreciate that staples havingdifferent geometries can also be fired from the staple cartridgesdescribed herein.

Referring again to FIG. 40, the staple line 4060 includes a firstportion 4061, a proximal portion 4063, and a distal portion 4065. Thefirst portion 4061 is generated from the first pattern, or majorpattern, 4030 and extends along a substantial portion of the staple line4030. Owing to the angular orientation of the staples 4062 in the firstportion 4030, the first portion 4061 is substantially flexible orcompliant. For example, because the angularly-oriented staples 4062 canrotate within the stapled tissue T while minimizing trauma to the tissueT, the first portion 4061 is configured to stretch or extendlongitudinally and/or laterally as the stapled tissue stretches.

The proximal portion 4063 is generated from the proximal pattern 4040and forms the proximal end of the staple line 4060. The distal portion4065 is generated from the distal pattern 4042 and forms the distal endof the staple line 4060. Owing to the parallel orientation of thestaples 4062 in the proximal portion 4063 and the distal portion 4065 ofthe staple line 4060, the proximal portion 4063 and the distal portion4065 of the staple line 4060 can be less flexible than the first portion4061. However, the reduced flexibility of the proximal portion 4063 andthe distal portion 4065 may not impact, or not substantially impact, theoverall flexibility of the staple line 4060. Moreover, as describedherein, the proximal portion 4063 and the distal portion 4065 may notextend adjacent to the cutline and, in certain instances, the proximalportion 4063 may be absent or missing from the staple line 4060.

As described herein, staples are removably positioned in a staplecartridge and fired from the staple cartridge during use. In variousinstances, the staples can be driven out of staple cavities in thestaple cartridge and into forming contact with an anvil. For example, afiring element can translate through the staple cartridge during afiring stroke to drive the staples from the staple cartridge toward ananvil. In certain instances, the staples can be supported by stapledrivers and the firing element can lift the staple drivers to eject orremove the staples from the staple cartridge.

An anvil can include a staple-forming undersurface having staple-formingpockets defined therein. In certain instances, the staple-formingpockets can be stamped in the anvil. For example, the staple-formingpockets can be coined in a flat surface of the anvil. The reader willappreciate that certain features of the staple-forming pockets can be adeliberate consequence of a coining process. For example, a certaindegree of rounding at corners and/or edges of the staple-forming producecan be an intentional result of the coining process. Such features canalso be designed to better form the staples to their formedconfigurations, including staples that become skewed and/or otherwisemisaligned during deployment.

Each staple in the staple cartridge can be aligned with a staple-formingpocket of the anvil. In other words, the arrangement of staple cavitiesand staples in a staple cartridge for an end effector can correspond ormatch the arrangement of staple-forming pockets in an anvil of the endeffector. More specifically, the angular orientation of each staplecavity can match the angular orientation of the respectivestaple-forming pocket. For example, when the staple cavities arearranged in a herringbone pattern, the staple-forming pockets can alsobe arranged in a herringbone pattern.

When staples are driven from the staple cartridge and into formingcontact with the anvil, the staples can be formed into a “fired”configuration. In various instances, the fired configuration can be a“B-form” configuration, in which the tips of the staple legs are benttoward the staple base or crown to form a capital letter B havingsymmetrical upper and lower loops. In other instances, the firedconfiguration can be a modified B-form, such as a skewed B-formconfiguration, in which at least a portion of a staple leg torques outof plane with the staple base, or an asymmetrical B-form configuration,in which the upper and lower loops of the capital letter B areasymmetric. Tissue can be captured or clamped within the formed staple.

The arrangement of staples and/or staple cavities in a staple cartridgecan be configured to optimize the corresponding arrangement ofstaple-forming pockets in the forming surface of a complementary anvil.For example, the angular orientation and spacing of staples in a staplecartridge can be designed to optimize the forming surface of an anvil.In certain instances, the footprint of the staple-forming pockets in ananvil can be limited by the geometry of the anvil. In instances in whichthe staple-forming pockets are obliquely-oriented relative to alongitudinal axis, the width of the anvil can limit the size and spacingof the obliquely-oriented staple-forming pockets. For example, the widthof an intermediate row of staple-forming pockets can define a minimumdistance between a first row (e.g. an outer row) on one side of theintermediate row and a second row (e.g. an inner row) on the other sideof the intermediate row. Moreover, the rows of staple-forming pocketsare confined between an inside edge on the anvil, such as a knife slot,and an outside edge of the anvil.

In various instances, the pockets can be adjacently nested along astaple-forming undersurface of the anvil. For example, an intermediatepocket can be nested between an inner pocket and an outer pocket. Theangular orientation of the pockets can vary row-to-row to facilitate thenesting thereof. For example, the staple-forming pockets in an inner rowcan be oriented at a first angle, the staple-forming pockets in anintermediate row can be oriented at a second angle, and thestaple-forming pockets in an outer row can be oriented at a third angle.The first angle, the second angle, and the third angle can be different,which can facilitate the close arrangement of the staple-formingpockets.

Referring again to the previous staple cartridge depicted in FIG. 39 andother previous staple cartridges disclosed in, for example, U.S. Pat.No. 9,801,627, entitled FASTENER CARTRIDGE FOR CREATING FLEXIBLE STAPLELINES and/or U.S. patent application Ser. No. 14/498,145, filed Sep. 26,2014, now U.S. Patent Application Publication No. 2016/0089142, entitledMETHOD FOR CREATING A FLEXIBLE STAPLE LINE, the varying angles of thestaples and the staple cavities in each row can be selected to optimizethe nesting of the staple-forming pockets in a complementary anvil. Foreach such staple cartridge, a complementary anvil can be configured tohave a corresponding arrangement of staple-forming pockets. Moreover,the staple-forming pockets in the complementary anvils can be largerthan the staple cavities in an effort to facilitate the staple legs landor fall within the staple-forming pockets. For example, the staple legsmay be biased outward, such as in the case of V-shaped staples (see FIG.42) and the larger footprint of the staple-forming pockets can catch theoutwardly-biased staple legs during firing. In various instances, thestaple-forming pockets can be 0.005 inches to 0.015 inches longer thanthe corresponding staple cavities and/or staples. Additionally oralternatively, the staple-receiving cups of each staple-forming pocketcan be 0.005 inches to 0.015 inches wider than the corresponding staplecavities. In other instances, the difference in length and/or width canbe less than 0.005 inches or more than 0.015 inches.

In instances in which the size of the staples varies within a staplecartridge, the size of the staple-forming pockets can corresponding varywithin a complementary anvil. Varying the size of the staple-formingpockets can further facilitate the nesting thereof. For example, ininstances in which staple-forming pockets in an intermediate row areshorter than the staple-forming pockets in an inner row or an outer row,the width of the intermediate row of staple-forming pockets can bereduced, which can minimize the requisite spacing between the inner rowand the outer row.

The spacing of the staple-forming pockets can also be configured tooptimize the nesting thereof. For example, the pockets arranged in aninner row can be longitudinally staggered relative to the pocketsarranged in an outer row. Moreover, the pockets in the inner row canpartially longitudinally overlap the pockets in the outer row. Thepockets in an intermediate row can be longitudinally staggered relativeto the pockets in the inner row and the pockets in the outer row. Forexample, the pockets in the intermediate row can be equidistantlylongitudinally offset from the pockets in the outer row and the pocketsin the inner row

Anvils that are configured for use in surgical stapling applications maybe formed using various manufacturing techniques and methods. Oneprevious manufacturing method for fabricating surgical stapler anvilscomprises the process of “coining”. “Coining” is a form of precisionstamping in which the anvil material is subjected to sufficiently highstress to induce plastic flow on the surface of the material. Coining iscommonly accomplished using a gear driven press, a hydraulic press or amechanical press. Coining typically requires higher tonnage presses thanare typically used in conventional stamping processes because theworkpiece is plastically deformed and not actually cut. Although coininghas been an effective way to form staple-forming pockets in thestaple-forming undersurface of an anvil, it can result in the creationof some undesirable characteristics in the finished anvil.

In various previous anvil fabrication methods where coining is employed,the anvil raw material, which may comprise a metal material such asstainless steel or the like, is typically initially extruded or rolledinto an initial blank or body. The anvil body can then be machined usingvarious conventional machining techniques so as to initially form planarforming surfaces on each size of an elongate slot formed in the body.Once the body has been machined so that the forming surfaces are flat,the forming pockets are then coined in the forming surfaces in a desiredpattern.

FIG. 43 depicts a portion of a previous anvil 8300 in cross-section.This previous anvil comprises an anvil body 8310 that consists of leftand right staple-forming undersurfaces 8330L, 8330R that are separatedby an elongate slot 8326. The anvil body portion 8310 may be extruded orrolled out of 304 stainless steel or similar material. The elongate slot8326 and the anvil forming surfaces 8330L, 8330R are commonly machinedflat prior to the formation of the staple-forming pockets 8360 therein.An anvil cover 8390, which may be manufactured from 17-4PH stainlesssteel, is welded to the body portion 8310 at joints 8392 with welds8394. FIG. 44 comprises a photograph taken using a scanning electronmicroscope of a weld joint 8392 of a previous anvil 8300 showing thedifferent grain structures of the anvil body 8310 and anvil cover 8390as well as of the weld 8394.

FIG. 45 depicts a portion of the anvil 8300 in cross-section prior tothe formation of the staple-forming pockets 8360 therein using aprevious coining method. As can be seen in that Figure, a formingsurface 8330R has been machined flat on one side of the elongate slot8326 that was also machined into the anvil body 8310 using conventionalmachining methods and techniques. The Figure illustrates a crystallinestructure 8312 of the anvil body material prior to the coiningoperation. The desired final staple-forming pocket 8360 configuration isillustrated in phantom lines. FIG. 46 illustrates the anvil body 8310after the staple-forming pocket 8360 has been coined therein. Thecoining operation consists of striking the forming surface 8330 with adie (not shown) which results in high material displacement which leadsto high material density (lines 8314) around the formed pocket 8360.FIG. 47 is a photograph of a cross-section of a portion of a previousanvil 8300 using a scanning electron microscope. The photographillustrates the extensive grain deformation and occlusions formed belowthe pockets 8360 as a result of the coining process.

FIG. 48 is a photograph taken of a portion of the previous anvil body8310 that is below a pocket 8360 after the coining process. FIGS. 49 and50 comprise photographs of the region below the coined pocketsillustrating inclusions 8397 formed in the material. These elongatenon-metallic inclusions 8397 are typically found in a wrought product.The directionality of the inclusions indicates that the material wasrolled or extruded. FIG. 51 comprises a higher magnification photographof a portion of a previous anvil 8300 in an area that was not coinedillustrating non-metallic inclusions 8398 and 8399 therein.

In addition to the previous coining process employed to form theprevious anvil 8300, once the forming pockets 8360 have been coined intothe forming surfaces 8330L, 8330R, the forming surfaces 8330L, 8330R andpockets 8360 may be brushed and ultrasonically cleaned to remove anylubrication and debris resulting from the coining process. FIG. 52comprises a photograph of a portion of the previous anvil 8300 after thecleaning processes. FIGS. 53 and 54 are photographs of bottom portionsof one of the forming pockets 8360 showing some of the metal smearing8361 that results from the coining process. As illustrated in FIGS.47-51 and 53 and 54, the above-described previous method of anvilmanufacturing may result in the formation of an anvil with undesirableinclusions in the anvil body which may weaken the anvil. Such processmay also result in the formation of staple-forming pockets that haveundesirably rough forming surfaces.

FIGS. 55-59 illustrate a method 8400 that may avoid some of theaforementioned problems commonly encountered when using previous anvilmanufacturing methods. In at least one configuration, the method 8400involves employing a process of metal injection molding (“MIM”) forforming an anvil body portion 8510 of an anvil 8500. MIM is a metalworking process in which finely-powdered metal is mixed with bindermaterial to create a “feedstock” (action 8402) that is shaped andsolidified into an anvil body 8510 using injection molding (8404). Aftermolding (8404), the anvil body 8510 undergoes conditioning operations toremove the binder and to densify the powders (debinding-8406). In atleast one configuration, the MIM process is used to create an anvil body8510 that has a plurality of “preliminary” staple-forming pocketconfigurations that have a “near net configuration” or a near net“geometry”, which differs from “final” desired pocket configuration orgeometry. For example, a preliminary pocket configuration may have asimilar shape as a final pocket configuration, but the final pocketconfiguration may comprise a larger and deeper void or pocket in theanvil body.

More specifically and with reference to FIG. 56, a portion of the anvilbody 8510 is shown after the anvil body 8510 has been formed using theMIM process (for example—actions 8402, 8404, 8406). In at least onearrangement, the anvil body 8510 has been initially formed with a flator planar staple-forming undersurface 8430 that has a plurality ofstaple-forming pockets 8560P formed therein that each have a “near net”shape or geometry or a “pre-shape”. In the example illustrated incross-section in FIG. 56, a “pre-formed” pocket 8560P includes a bottomsurface 8532P and two sloping side walls 8534P. The sloping sidewalls8534P form a pocket opening that has a preliminary width “PW” (incross-section). The bottom surface 8532P is located a preliminary depth“PD” from the staple-forming undersurface 8530. The desired final pocketshape 8360F is illustrated in segmented lines in FIG. 56. Once the anvilbody 8510 has been formed with the “pre-shaped” or “preliminary” pockets8360P, a coining process 8408 is employed to form the final formingpockets 8560F therein.

FIG. 57 illustrates a final forming pocket 8560F that has been formedinto the anvil body 8510. As can be seen in that Figure, the finalforming pocket 8560F includes a final bottom surface 8532F and twosloping sidewalls 8534F that define a pocket opening with a final width“FW”. The final bottom surface 8532F is located a final depth “FD” fromthe forming surface 8530. In the illustrated example, FW>PW and FD>PD.The cross-sectional shape of the forming pockets 8560P, 8560F depictedin FIGS. 56 and 57 are for illustrative purposes only and should not belimiting. The shapes of the pockets may vary with a final forming pocketbeing larger than the preliminary or pre-shaped forming pocket. Whilethe geometric shape of the final pocket 8560F may be similar to thepreformed pocket 8560P geometry, the final pocket 8560F will be largerthan the preformed pocket 8560P due to the coining process 8408. Inaddition, the pre-surface finish 8536P of the pre-formed pocket 8560P asa result of the MIM processes 8402. 8404, 8406, may be different fromthe final surface finish 8536F of the final pocket 8560F as a result ofthe coining process 8408. For example, the pre-surface finish 8536P maybe rougher than the final surface finish 8536F. FIG. 58 illustrates apreliminary or pre-shaped forming pocket 8560P that has beenpreliminarily formed using the MIM process. As can be seen in thatFigure, the surface finish 8536P of the forming pocket 8560P can besomewhat rougher than the final surface finish 8536F of the finalforming pocket 8560F (shown in FIG. 59) that is formed by the finalcoining process 8408. Because the preliminary or pre-shaped formingpockets have a pre-shape, the coining process is performed with a lowerforce than is typically used in previous coining operations. Such lowercoining force results in less material displacement and lowercompression than is typically experienced when using previous coiningoperations. In an alternative method, the coining process may bereplaced with a forging process. In this alternative method, forexample, after the anvil body has been formed with previous or preformedforming pockets using the above-described MIM process, the anvil bodymay be heated while it is struck with a forging die that is configuredto form the final forming pockets therein in manner described above.

FIGS. 60-64 illustrate an alternative use of the method 8400′ to formstaple-forming pockets 8560F′in the anvil body material 8510. In thismethod 8400′, the preformed pocket configuration 8560P′ is formed with arelatively final shape and size, except for the provision of a stapleleg guidance groove also referred to as a “staple-forming path” 8570therein. The staple-forming path 8570 is coined into the bottom surface8532P of the pocket (action 8408′). The staple-forming path 8570 is onlycoined in the bottom 8532P of the pocket 8560P′ to form the pocket8560F′. See FIGS. 63 and 64. As can be seen in FIG. 64, thestaple-forming path 8570 is smoother than the surrounding surfacesformed by the MIM process. That is, the surface finish 8572F′ of thestaple-forming path 8570 is smoother than the surface finish 8536P′ ofthe remaining walls of pocket 8560F′. The staple-forming path 8570 isalso harder and denser than the MIM formed portions due to thecompression attained from coining. However, the problems associated withprevious coining operations are less likely to occur due to the lowerforces and compressions attained using the method 8400′.

Another anvil manufacturing method 8600 is depicted in FIG. 65. Method8600 involves forming the anvil body 8510 using liquid metal orVitreloy. The liquid metal process is employed to form the anvil body8510 with the anvil pockets 8560P in their near net shape (action 8602).As with method 8600, a coining process 8604 is used to provide theforming pockets 8560F with their final configurations. FIG. 66 depicts amethod 8600′ that comprises using the liquid metal process to form theanvil body 8510 with pockets that have their final shape (action 8602′)and then coining the staple-forming path 8570 into each pocket (action8604′). As with the process 8400 described above, the final formingpockets 8560F may have a similar geometric shape as the pre-formed ornear net forming pockets 8560P with the final forming pockets 8560Fbeing larger and deeper.

Another anvil manufacturing method 8700 is depicted in FIG. 67. Method8700 comprises extruding or rolling an initial blank or body that issized and shaped to be machined into a desired final configuration(action 8702). The anvil body is machined using various conventionalmachining techniques so as to initially form planar forming surfaces oneach size of the elongate slot. In addition, in this arrangement, themethod involves machining the pre-formed or initial pockets 8560P intothe planar forming surfaces (action 8704). The pre-formed pocket 8560Pmay be similar to the preformed pocket configurations such as thosedepicted in FIG. 56, for example. Thereafter, the final pocketconfigurations 8560F are formed by coining to attain the configurationsuch as that depicted in FIG. 57 (action 8706). In using method 8700,however, the anvil body is not created using MIM or liquid metal.Instead, the anvil body material may be extruded or rolled and thenmachined. However, because the coining forces needed are lower than thepreviously used coining methods, the compression and materialdisplacement will be lower. FIG. 68 depicts a method 8700′ thatcomprises extruding or rolling an initial blank or body that is sizedand shaped to be machined into a desired final configuration (action8702). The anvil body is machined using various conventional machiningtechniques so as to initially form the pockets into the planar formingsurfaces on each size of the elongate slot. Coining (action 8706′) isthen employed to coin the staple-forming pass 8570 into each pocket.

FIG. 69 depicts another method 8800 that employs the action 8402 tocreate the feedstock. The anvil body in this method is injection molded(action 8404′) in final form, but without any anvil pockets formedtherein. The anvil body is then conditioned (action 8406). The preformedpockets 8560P are then machined into the anvil body (action 8808). Thefinal pockets 8560F are then formed into the anvil body by coining(action 8810). FIG. 70 depicts another method 8800′ that is similar tomethod 8800, except that the pockets are machined with their finalconfiguration (action 8808′). The staple-forming paths are then coinedinto the bottom of each pocket (action 8810′).

FIG. 71 depicts another method 8900 wherein the anvil body is formedusing liquid metal (action 8902). Near-net pockets are then machinedinto the anvil body (action 8904). The final pocket configurations arethen coined into the anvil body (action 8906). FIG. 72 depicts anothermethod 8900′ that is similar to method 8900, except that the pockets aremachined with their final configuration (action 8904′). Thestaple-forming paths are then coined into the bottom of each pocket(action 8906′). In alternative arrangements, the preformed pockets 8560Pmay be formed in the anvil body 8510 using electrochemical machining(ECM). ECM is a method of removing metal by an electrochemical process.ECM is similar to electrical discharge machining (EDM) in that a highcurrent is passed between an electrode and the part through anelectrolytic material removing process having a negatively chargedelectrode (cathode), a conductive fluid (electrolyte) and a conductiveworkpiece (anode). The ECM cutting tool is guided along the desired pathclose to the work, but without touching the piece. Once the preformedpockets are formed in the anvil body using the ECM process, the finalpocket form or the staple-forming path is coined into each pocket.

By forming the anvil body using the MIM process or the liquid metalprocess, the irregularities and inclusions often encountered inprocesses wherein the anvil body is extruded or rolled may be avoided.By preforming the pockets in the anvil body using the various methodsdescribed herein prior to coining enables lower coining forces to beemployed when forming the final pocket configuration or staple-formingpath. Such lower coining forces result in lower compression and lessmaterial displacement and consequently a reduction in the irregularitiesand occlusions commonly encountered when employing previous anvilfabrication methods.

EXAMPLES

Example 1—A method of manufacturing an anvil for a surgical stapler,wherein the method comprises providing anvil material and establishing atissue contacting surface in the anvil material. The method furthercomprises forming a staple-forming pocket into the anvil materialthrough the tissue contacting surface. The forming action comprisesemploying a first manufacturing process to establish the staple-formingpocket in the anvil material with a preliminary geometric shape and apreliminary surface finish and employing a second manufacturing processthat differs from the first manufacturing process to change thepreliminary geometric shape of the staple-forming pocket to a desiredfinal geometric shape that differs from the preliminary geometric shapeand includes a final desired surface finish that differs from thepreliminary surface finish.

Example 2—The method of Example 1, wherein the preliminary geometricshape comprises a preliminary bottom surface that is located apreliminary depth from the tissue contacting surface. The preliminarygeometric shape further comprises at least two preliminary sloping wallsthat extend from opposing sides of the preliminary bottom surface to thetissue contacting surface to form a preliminary pocket opening thereinthat comprises a preliminary opening width. The desired final geometricshape comprises a final bottom surface that is located a final depthfrom the tissue contacting surface, wherein the final depth is greaterthan the preliminary depth. The desired final geometric shape furthercomprises at least two final sloping walls that extend from opposingsides of the final bottom surface to the tissue contacting surface toform a final pocket opening therein that comprises a final openingwidth, wherein the final opening width is greater than the preliminaryopening width.

Example 3—The method of Examples 1 or 2, wherein the first manufacturingprocess is selected from the group of first manufacturing processesconsisting of: electrochemical machining, metal injection molding, andliquid metal forming processes.

Example 4—The method of Examples 1, 2 or 3, wherein the secondmanufacturing process is selected from the group of second manufacturingprocesses consisting of: coining and forging.

Example 5—The method of Examples 1, 2, 3 or 4, wherein only a portion ofthe desired final geometric shape includes the final desire surfacefinish.

Example 6—The method of Examples 1, 3, 4 or 5, wherein the preliminarygeometric shape comprises a preliminary bottom surface that is located apreliminary depth from the tissue contacting surface. The preliminarygeometric shape further comprises at least two sloping walls that extendfrom opposing sides of the preliminary bottom surface to the tissuecontacting surface to form a pocket opening therein and wherein thedesired final geometric shape comprises a final bottom surface whereinat least a portion thereof is located a final depth from the tissuecontacting surface wherein the final depth is greater than thepreliminary depth and wherein the at least a portion of the final bottomsurface includes the final desired surface finish.

Example 7—The method of Example 6, wherein at least a portion of thefinal bottom surface comprises a staple leg guidance groove in the finalbottom surface.

Example 8—The method of Examples 6 or 7, wherein the first manufacturingprocess is selected from the group of first manufacturing processesconsisting of: electrochemical machining, metal injection molding, andliquid metal forming processes.

Example 9—The method of Examples 6, 7 or 8, wherein the secondmanufacturing process is selected from the group of second manufacturingprocesses consisting of: coining and forging.

Example 10—The method of Examples 6, 7, 8 or 9, wherein the secondmanufacturing process is only applied to at least a portion of thepreliminary bottom surface and not to the at least two sloping walls.

Example 11—The method of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10,wherein the second manufacturing process is employed to change thepreliminary geometric shape of the staple-forming pocket to anintermediate geometric shape that differs from the preliminary geometricshape and wherein the method further comprises employing a thirdmanufacturing process to change the intermediate geometric shape of thestaple-forming pocket to a desired final geometric shape that differsfrom the intermediate geometric shape and includes a final desiredsurface finish that differs from the preliminary surface finish.

Example 12—The method of Examples 1, 2, 3, 4, 5, 6, 6, 8, 9 or 10,wherein the second manufacturing process is employed to change thepreliminary geometric shape of the staple-forming pocket to anintermediate geometric shape that differs from the preliminary geometricshape and includes a intermediate surface finish that differs from thepreliminary surface finish and wherein the method further comprisesemploying a third manufacturing process to change the intermediategeometric shape of the staple-forming pocket to a desired finalgeometric shape that differs from the intermediate geometric shape andat least a portion thereof includes a final desired surface finish thatdiffers from the intermediate surface finish.

Example 13—A method of manufacturing an anvil for a surgical stapler,wherein the method comprises providing anvil material and establishing atissue contacting surface in the anvil material. The method furthercomprises forming a staple-forming pocket into the anvil materialthrough the tissue contacting surface. The forming action comprisesemploying a first manufacturing process to establish the staple-formingpocket in the anvil material with a preliminary geometric shape andemploying a second manufacturing process to change the preliminarygeometric shape of the staple-forming pocket to a desired finalgeometric shape that differs from the preliminary geometric shape.

Example 14—The method of Example 13, wherein the preliminary geometricshape comprises a bottom surface that is located a depth from the tissuecontacting surface. The preliminary geometric shape further comprises atleast two sloping walls that extend from opposing sides of the bottomsurface to the tissue contacting surface to form a pocket openingtherein and wherein the second manufacturing process comprises forming astaple leg guiding groove in the bottom surface.

Example 15—The method of Example 14, wherein the second manufacturingprocess comprises coining the staple leg-guiding groove into the bottomsurface.

Example 16—The method of Examples 14 or 15, wherein the bottom surfaceincludes a first surface finish and wherein the staple leg guidinggroove includes a second surface finish that differs from the firstsurface finish.

Example 17—The method of Example 13, wherein the preliminary geometricshape comprises a preliminary bottom surface located a preliminary depthfrom the tissue contacting surface. The preliminary geometric shapefurther comprises at least two sloping walls that extend from opposingsides of the preliminary bottom surface to the tissue contacting surfaceto form a pocket opening therein and wherein the desired final geometricshape comprises a final bottom surface, at least a portion of which islocated a final depth from the tissue contacting surface wherein thefinal depth is greater than the preliminary depth and wherein the atleast a portion of the final bottom surface is smoother and harder thanthe preliminary bottom surface.

Example 18—The method of Examples 13, 14, 15, 16 or 17, wherein thefirst manufacturing process is selected from the group of firstmanufacturing processes consisting of: electrochemical machining, metalinjection molding and liquid metal forming processes.

Example 19—The method of Examples 13, 14, 15, 16, 17 or 18, wherein thesecond manufacturing process is selected from the group of secondmanufacturing processes consisting of: coining and forging.

Example 20—The method of Examples 13, 14, 15, 16, 17, 18 or 19, whereinthe second manufacturing process is only employed to change a portion ofthe preliminary geometric shape.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE,which issued on Apr. 4, 1995;

U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVINGSEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21,2006;

U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING ANDFASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued onSep. 9, 2008;

U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL INSTRUMENTWITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which issued on Dec.16, 2008;

U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING ANARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;

U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, whichissued on Jul. 13, 2010;

U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLEFASTENER CARTRIDGE, which issued on Mar. 12, 2013;

U.S. patent application Ser. No. 11/343,803, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No. 7,845,537;

U.S. patent application Ser. No. 12/031,573, entitled SURGICAL CUTTINGAND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008;

U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FORA SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, nowU.S. Pat. No. 7,980,443;

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/235,972, entitled MOTORIZED SURGICALINSTRUMENT, now U.S. Pat. No. 9,050,083.

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROLASSEMBLY, filed Dec. 24, 2009; now U.S. Pat. No. 8,220,688;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE,filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;

U.S. patent application Ser. No. 13/036,647, entitled SURGICAL STAPLINGINSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No. 8,561,870;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat.No. 9,072,535;

U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012;now U.S. Pat. No. 9,101,358;

U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Pat.No. 9,345,481;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. PatentApplication Publication No. 2014/0263552;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICALCUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM,filed Jan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by referenceherein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

What is claimed is:
 1. A method of manufacturing an anvil for a surgicalstapler, said method comprising: providing anvil material; establishinga tissue contacting surface in the anvil material; and forming astaple-forming pocket into the anvil material through the tissuecontacting surface, wherein said forming comprises: employing a firstmanufacturing process to establish the staple-forming pocket in theanvil material with a preliminary geometric shape and a preliminarysurface finish; and employing a second manufacturing process thatdiffers from the first manufacturing process to change the preliminarygeometric shape of the staple-forming pocket to a desired finalgeometric shape that differs from the preliminary geometric shape andincludes a final desired surface finish that differs from thepreliminary surface finish.
 2. The method of claim 1, wherein thepreliminary geometric shape comprises: a preliminary bottom surfacelocated a preliminary depth from the tissue contacting surface; and atleast two preliminary sloping walls extending from opposing sides of thepreliminary bottom surface to the tissue contacting surface to form apreliminary pocket opening therein that comprises a preliminary openingwidth and wherein the desired final geometric shape comprises: a finalbottom surface located a final depth from the tissue contacting surface,wherein the final depth is greater than the preliminary depth; and atleast two final sloping walls extending from opposing sides of the finalbottom surface to the tissue contacting surface to form a final pocketopening therein that comprises a final opening width, wherein the finalopening width is greater than the preliminary opening width.
 3. Themethod of claim 1, wherein said first manufacturing process is selectedfrom the group of first manufacturing processes consisting of:electrochemical machining, metal injection molding, and liquid metalforming processes.
 4. The method of claim 1, wherein said secondmanufacturing process is selected from the group of second manufacturingprocesses consisting of: coining and forging.
 5. The method of claim 2,wherein only a portion of the desired final geometric shape includes thefinal desired surface finish.
 6. The method of claim 1, wherein thepreliminary geometric shape comprises: a preliminary bottom surfacelocated a preliminary depth from the tissue contacting surface; and atleast two sloping walls extending from opposing sides of the preliminarybottom surface to the tissue contacting surface to form a pocket openingtherein and wherein the desired final geometric shape comprises a finalbottom surface wherein at least a portion thereof is located a finaldepth from the tissue contacting surface wherein the final depth isgreater than the preliminary depth and wherein at least a portion of thefinal bottom surface includes the final desired surface finish.
 7. Themethod of claim 6, wherein the at least a portion of the final bottomsurface comprises a staple leg guidance groove in the final bottomsurface.
 8. The method of claim 6, wherein said first manufacturingprocess is selected from the group of first manufacturing processesconsisting of: electrochemical machining, metal injection molding, andliquid metal forming processes.
 9. The method of claim 8, wherein saidsecond manufacturing process is selected from the group of secondmanufacturing processes consisting of: coining and forging.
 10. Themethod of claim 9, wherein said second manufacturing process is onlyapplied to at least a portion of the preliminary bottom surface and notto the at least two sloping walls.
 11. The method of claim 1, whereinsaid second manufacturing process is employed to change the preliminarygeometric shape of the staple-forming pocket to an intermediategeometric shape that differs from the preliminary geometric shape andwherein said method further comprises employing a third manufacturingprocess to change the intermediate geometric shape of the staple-formingpocket to the desired final geometric shape that differs from theintermediate geometric shape and includes the final desired surfacefinish that differs from the preliminary surface finish.
 12. The methodof claim 1, wherein said second manufacturing process is employed tochange the preliminary geometric shape of the staple-forming pocket toan intermediate geometric shape that differs from the preliminarygeometric shape and includes a intermediate surface finish that differsfrom the preliminary surface finish and wherein said method furthercomprises employing a third manufacturing process to change theintermediate geometric shape of the staple-forming pocket to the desiredfinal geometric shape that differs from the intermediate geometric shapeand at least a portion thereof includes the final desired surface finishthat differs from the intermediate surface finish.
 13. A method ofmanufacturing an anvil for a surgical stapler, said method comprising:providing anvil material; establishing a tissue contacting surface inthe anvil material; and forming a staple-forming pocket into the anvilmaterial through the tissue contacting surface, wherein said formingcomprises: employing a first manufacturing process to establish thestaple-forming pocket in the anvil material with a preliminary geometricshape; and employing a second manufacturing process to change thepreliminary geometric shape of the staple-forming pocket to a desiredfinal geometric shape that differs from the preliminary geometric shape.14. The method of claim 13, wherein the preliminary geometric shapecomprises: a bottom surface located a depth from the tissue contactingsurface; and at least two sloping walls extending from opposing sides ofthe bottom surface to the tissue contacting surface to form a pocketopening therein and wherein said second manufacturing process comprisesforming a staple leg guiding groove in the bottom surface.
 15. Themethod of claim 14, wherein said second manufacturing process comprisescoining the staple leg guiding groove into the bottom surface.
 16. Themethod of claim 14, wherein the bottom surface includes a first surfacefinish and wherein the staple leg guiding groove includes a secondsurface finish that differs from the first surface finish.
 17. Themethod of claim 13, wherein the preliminary geometric shape comprises: apreliminary bottom surface located a preliminary depth from the tissuecontacting surface; and at least two sloping walls extending fromopposing sides of the preliminary bottom surface to the tissuecontacting surface to form a pocket opening therein and wherein thedesired final geometric shape comprises a final bottom surface, at leasta portion of which is located a final depth from the tissue contactingsurface wherein the final depth is greater than the preliminary depthand wherein the at least a portion of the final bottom surface issmoother and harder than the preliminary bottom surface.
 18. The methodof claim 13, wherein said first manufacturing process is selected fromthe group of first manufacturing processes consisting of:electrochemical machining, metal injection molding and liquid metalforming processes.
 19. The method of claim 18, wherein said secondmanufacturing process is selected from the group of second manufacturingprocesses consisting of: coining and forging.
 20. The method of claim19, wherein said second manufacturing process is only employed to changea portion of the preliminary geometric shape.